Earbud case with insert

ABSTRACT

An earbud includes a housing that includes a driver assembly positioned within the housing forming a front volume in front of the driver and a back volume behind the driver. An acoustic insert is positioned behind the driver assembly and attached to an interior surface of the housing such that it forms a bass channel that is routed from the back volume to a vent in the housing.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of U.S. patent application Ser. No.15/273,683, for “EARBUDS WITH ACOUSTIC INSERT” filed Sep. 22, 2016,which claims priority to U.S. provisional patent application Ser. No.62/235,205, for “EARBUD CASE WITH CHARGING SYSTEM” filed on Sep. 30,2015, to U.S. provisional patent application Ser. No. 62/235,213, for“CASE WITH MAGNETIC OVER-CENTER MECHANISM” filed on Sep. 30, 2015, toU.S. provisional patent application Ser. No. 62/235,219, for “MAGNETICRETENTION OF EARBUD WITHIN CAVITY” filed on Sep. 30, 2015, to U.S.provisional patent application Ser. No. 62/235,226, for “CASE WITHINDUCTIVE CHARGING SYSTEM” filed on Sep. 30, 2015 and to U.S.provisional patent application Ser. No. 62/384,114, for “CASE FORCHARGING AND RETAINING PORTABLE LISTENING DEVICES” filed on Sep. 6,2016, each of which is hereby incorporated by reference in its entiretyfor all purposes.

This application is related to the following concurrently filed andcommonly assigned U.S. nonprovisional patent applications:

U.S. nonprovisional patent application Ser. No. 15/273,671, Filed Sep.23, 2016, “EARBUD CASE WITH CHARGING SYSTEM”; U.S. nonprovisional patentapplication Ser. No. 15/273,675, Filed Sep. 23, 2016, “CASE WITHMAGNETIC OVER-CENTER MECHANISM; U.S. nonprovisional patent applicationSer. No. 15/273,677, Filed Sep. 23, 2016, “EARBUD CASE WITH WIRELESSRADIO SHUTDOWN FEATURE”; U.S. nonprovisional patent application Ser. No.15/273,685, Filed Sep. 23, 2016, “WIRELESS PAIRING OF EARBUDS AND CASE”;U.S. nonprovisional patent application Ser. No. 15/273,687, Filed Sep.23, 2016, “EARBUD CASE WITH RECEPTACLE CONNECTOR FOR EARBUDS”; U.S.nonprovisional patent application Ser. No. 15/273,690, Filed Sep. 23,2016, “WIRELESS EARBUDS WITH ELECTRONIC CONTACTS”; U.S. nonprovisionalpatent application Ser. No. 15/273,691, Filed Sep. 23, 2016, “MAGNETICRETENTION OF EARBUD WITHIN CAVITY”; U.S. nonprovisional patentapplication Ser. No. 15/273,693, Filed Sep. 23, 2016, “CASE WITHINDUCTIVE CHARGING TRANSMITTER TO CHARGE A PORTABLE DEVICE”; U.S.nonprovisional patent application Ser. No. 15/273,694, Filed Sep. 23,2016, “WATERPROOF RECEPTACLE CONNECTOR”; U.S. nonprovisional patentapplication Ser. No. 15/273,696, Filed Sep. 23, 2016, “EARBUDS WITHCAPACITIVE TOUCH SENSOR”; U.S. nonprovisional patent application Ser.No. 15/273,698, Filed Sep. 23, 2016, “CASE WITH TORSION SPRINGOVER-CENTER MECHANISM”; each of which is hereby incorporated byreference in its entirety for all purposes.

BACKGROUND

The described embodiments relate generally to portable listening devicessuch as earbuds and other types of headphones, and to cases for storingand charging such devices.

Portable listening devices can be used with a wide variety of electronicdevices such as portable media players, smart phones, tablet computers,laptop computers, stereo systems and other types of devices. Portablelistening devices have historically included one or more small speakersconfigured to be place on, in, or near a user's ear, structuralcomponents that hold the speakers in place, and a cable thatelectrically connects the portable listening device to an audio source.Other portable listening devices can be wireless devices that do notinclude a cable and instead, wirelessly receive a stream of audio datafrom a wireless audio source.

While wireless portable listening devices have many advantages overwired devices, they also have some potential drawbacks. For example,wireless portable listening devices, typically require one or morebatteries, such as a rechargeable battery, that provides power to thewireless communication circuitry and other components of the device.Single use batteries need to be replaced when their charge is depletedwhile rechargeable batteries need to be periodically recharged. Also, ifthe portable wireless listening device is a pair of wireless earbuds,the earbuds can be relatively small and easy to lose when not in use.Further, achieving high-end acoustic performance from the relativelysmall earbuds can challenge manufacturers due to the reduced amount ofspace available within each earbud.

SUMMARY

Some embodiments of the present disclosure relate to a case that canstore and charge a portable listening device, such as a pair of wirelessearbuds or other types of headphones. In various embodiments the casecan include one or more features that can improve the user experienceassociated with using the case and the portable listening device. Forexample, some embodiments of the disclosure pertain to a case forwireless earbuds that includes a detector that detects if the earbudsare stored in the case along with a detector that detects if a lid ofthe case is opened or closed. Circuitry within the case can useinformation from the detectors to improve the user experience associatedwith charging the earbuds, pairing the earbuds to a host device, such asa portable media player or other source of an audio signal, and/orturning one or more features of the earbuds off to extend the life ofany battery used to power the earbuds.

In other embodiments, a case for a portable listening device can includea lid that, when closed, encloses the listening device within the caseand when open exposes the stored listening device so that a user canremove the listening device from the case. The lid can be pivotablycoupled to a housing of the case with a bi-stable hinge with an overcenter configuration where the lid is in a stable position when it iseither closed or fully open and is unstable at positions in between suchthat the lid tends to move to the open or closed position. The bi-stableoperation of the lid can provide a positive user experience in openingand closing the lid as the lid moves easily, and with minimal effort,between closed and fully open positions. In other embodiments a case fora portable listening device can be configured to magnetically attractand retain the listening device within the case. Still other embodimentsfacilitate the pairing of a wireless portable listening device with ahost device and/or automatically turn OFF the wireless radio of awireless portable listening device when the device is stored and fullyenclosed within the case and automatically turn ON the wireless radioupon opening the case lid. Various embodiments of the disclosure caninclude all of the above features together or just some of the features.

In some embodiments a case for transporting and charging a portablelistening device that includes a rechargeable battery and a powercontact is provided. The portable listening device case can include ahousing configured to receive the portable listening device; a lidattached to the housing and operable between a closed position where thelid conceals the listening device within the case and an open positionwhere the lid is displaced from the housing such that a user can removethe listening device from the case; a detector configured to generate adetect signal when the listening device is placed in the housing; andcharging circuitry configured to initiate charging of the rechargeablebattery in response to receiving the detect signal.

In some embodiments a case for a pair of earbuds includes a housinghaving one or more cavities configured to receive the pair of earbuds; alid attached to the housing and operable between a closed position wherethe lid is aligned over the one or more cavities and an open positionwhere the lid is displaced from the one or more cavities; and a chargingsystem. The charging system can include a case battery; an earbuddetector configured to detect when an earbud is placed in the one ormore cavities; and charging circuitry configured to initiate charging ofthe earbud when the earbud detector detects that the earbud is insertedinto the one or more cavities. The one or more cavities can include afirst cavity configured to receive a first earbud in the pair of earbudsand a second cavity sized and shaped to receive a second earbud in thepair of earbuds. The earbud detector can include a first earbud sensorconfigured to detect when the first earbud is placed in first cavity anda second earbud sensor configured to detect when the second earbud isplaced in the second cavity.

In some embodiments a case for a pair of earbuds, each earbud having anear interface portion, a stem, an earbud battery and a wireless radio isprovided. The case can include: a housing having a first cavityconfigured to receive a first earbud in the pair of earbuds and a secondcavity configured to receive a second earbud in the pair of earbuds; alid attached to the housing and operable between a closed position wherethe lid conceals the earbuds within the case and an open position thatallows a user to remove the earbuds from the case; and a chargingsystem. The charging system can include a case battery; a firstconnector configured to interface to a power source for charging thecase battery; a second connector configured to couple to each of thefirst and second earbuds, the second connector having at least onecontact positioned in the first cavity and at least one contactpositioned in the second cavity; an earbud detector configured to detectwhen an earbud is placed in either of the first or second cavities; andcharging circuitry configured to initiate charging of an earbud batterywhen the earbud detector detects insertion of an earbud within eitherthe first cavity or the second cavity and configured to cease chargingthe earbud when the earbud detector detects an earbud is removed fromthe cavity.

Some embodiments of the disclosure pertain to a case that can be used tostore a portable listening device or another type of electronic device.The case can include: a housing having a cavity to receive theelectronic device and a receiving opening that communicates with thereceiving opening; a lid secured to housing with a pivotable joint, thelid being operable between an open position in which the receivingopening is exposed and a closed position in which the lid covers thereceiving opening; and a plurality of magnetic elements disposed withinthe housing and the lid, the plurality of magnetic elements configuredto create an over center position for the lid such that the lid resistsrotating from the open position to the closed position until the lid ismoved past the over center position when the lid is then attracted tothe closed position.

In some embodiments a case for a portable listening device is provided.The case can include: a housing having a cavity to receive the listeningdevice; a lid attached to the housing with a pivotable joint allowingthe lid to rotate between a closed position where the lid is alignedover the cavity and an open position where the lid is angularlydisplaced allowing the listening device to be removed from the cavity;and a plurality of magnetic elements disposed within the housing and thelid, the plurality of magnetic elements configured to secure the lid inthe closed position and to resist the lid moving from the open positionto the closed position. The plurality of magnetic elements can include afirst pair of magnetic elements configured to repel each other and asecond pair of magnetic elements configured to attract each other. Thefirst pair of magnetic elements can include a first magnet positioned inthe lid adjacent to the pivotable joint and a second magnet positionedin the housing adjacent to the pivotable joint and oriented to repel thefirst magnet. The second pair of magnetic elements can include a firstmagnetic element positioned in the lid opposite the pivotable joint anda second magnetic element positioned in a housing wall opposite thepivotable joint and oriented to attract the first magnetic element. Insome instances both of the magnetic elements of the second pair ofmagnetic elements are magnets. In some instances one of the magneticelements of the second pair of magnetic elements is a magnet and theother magnetic element is a magnetic material.

In some embodiments, a case for a portable listening device includes: ahousing having a cavity to receive the listening device and a receivingopening that communicates with the cavity; a lid secured to housing witha pivotable joint, the lid being operable between an open position inwhich the receiving opening is exposed and a closed position in whichthe lid covers the receiving opening; a first magnetic element locatedin the lid proximate the pivotable joint and oriented to repel a secondmagnetic element located in the housing proximate the pivotable joint;and a third magnetic element located in the lid at a distal end of thelid opposite the pivotable joint and oriented to attract a fourthmagnetic element located in the housing at a distal end of the housingopposite the pivotable joint; wherein the first, second, third andfourth magnetic elements cooperate to define an over center position forthe lid disposed between the open position and the closed position suchthat that the lid resists rotating from the open position to the closedposition until the lid is moved past the over center position where thelid is impelled to the closed position.

Some embodiments pertain to a case for a portable listening devicehaving a wireless radio where the case includes: a housing having acavity configured to receive the portable listening device; a lidattached to the housing and operable between a closed position where thelid conceals the portable listening device within the case and an openposition where the lid is displaced from the housing such that a usercan remove the portable listening device from the case; a lid sensor todetect if the lid is in the closed position or the open position; andcircuitry configured to turn ON the wireless radio when the lid sensordetects that the lid is moved from the closed position to the openposition. The lid sensor can generate an open signal when the lid movesfrom a closed position to an open position, and the circuitry can beconfigured to turn ON the wireless radio in response to the open signal.In some instances the case can further include an electrical connectorhaving a first contact positioned within the cavity to electricallyconnect to a second contact on the portable listening device when theportable listening device is received within the cavity, and the casethe circuitry can turn ON the wireless radio in the portable listeningdevice by sending an instruction to the portable listening device overthe first contact.

In some embodiments a case for a portable listening device having awireless radio includes: a housing having a cavity configured to receivethe portable listening device; a lid attached to the housing andoperable between a closed position where the lid conceals the portablelistening device within the case and an open position where the lid isdisplaced from the housing such that a user can remove the portablelistening device from the case; a device detector configured to detectwhen the portable listening device is placed in the cavity; a lid sensorto detect if the lid is in the closed position or the open position; andcircuitry configured to turn OFF the wireless radio when the lid sensordetects that the lid is moved from the open position to the closedposition. The lid sensor can generate a close signal when the lid movesfrom an open position to a closed position, and the circuitry can beconfigured to turn OFF the wireless radio in response to the closesignal. In some instances the case can further include an electricalconnector having a first contact positioned within the cavity toelectrically connect to a second contact on the portable listeningdevice when the portable listening device is received within the cavity,and the case the circuitry can turn OFF the wireless radio in theportable listening device by sending an instruction to the portablelistening device over the first contact.

In some embodiments a case for a pair of earbuds can include: a housinghaving a first cavity configured to receive a first earbud in the pairof earbuds and a second cavity configured to receive a second earbud inthe pair of earbuds; a lid attached to the housing and operable betweena closed position where the lid conceals the earbuds within the case andan open position that allows a user to remove the earbuds from the case;a lid sensor to detect if the lid is in the closed position or the openposition; a case battery; circuitry configured charge an earbud batterywithin each earbud; and circuitry configured to turn ON a wireless radioin an earbud when the lid sensor detects that the lid is moved from theclosed position to the open position and to turn OFF the wireless radioin an earbud when the lid sensor detects that the lid is moved from theopen position to the closed position. In some embodiments, the lidsensor can generate an open signal when the lid moves from a closedposition to an open position and generate an close signal when the lidmoves from an open to a closed position, and the circuitry includedwithin the case can be configured to turn ON the wireless radio inresponse to the open signal and to turn OFF the wireless radio inresponse to the close signal. In various embodiments the case canfurther include a device detector that detects when a portable listeningdevice is received within the cavity, and circuitry within the case canbe configured to only send instructions to the portable listening deviceto turn the wireless radio ON or OFF if the device detector detects thatthe portable listening device is received within the cavity. In variousexamples, the lid sensor can be a Hall-effect sensor.

Some embodiments of the disclosure pertain to an earbud that includes: ahousing having a non-occluding ear portion; a directional sound portdisposed in the non-occluding ear portion; a driver assembly positionedwithin the housing having a front volume disposed in front of the driverassembly and a back volume disposed behind the driver assembly; and anacoustic insert positioned within the housing behind the driver assemblyand attached to an interior surface of the housing such that theacoustic insert and the housing form a bass channel that is routed fromthe back volume to a multiport vent within the housing. The acousticinsert can include a recess defined by raised weld regions that areacoustically bonded to the interior surface of the housing. In someinstances the recess within the acoustic insert forms three walls of thebass channel and the housing forms a fourth wall of the bass channel.The acoustic insert can further include an aperture that couples thefront volume to the multiport vent, and the bass channel and theaperture can be coupled to a multiport chamber that is vented throughthe multiport vent. In some examples the acoustic insert is formed froma carbon doped plastic that absorbs laser energy. In some examples, theearbud housing can be made from Acrylonitrile butadiene styrene (ABS)with a titanium dioxide pigment.]

An earbud according to some embodiments can include: a housing having anear portion coupled to a stem; a cavity formed within the ear portion; adriver assembly positioned within the cavity and defining a front volumedisposed in front of the driver assembly and a back volume disposedbehind the driver assembly; an acoustic insert positioned within thecavity behind the driver assembly and attached to an interior surface ofthe housing; and a bass channel formed by the acoustic insert and thehousing that is routed from the back volume to an external environmentvia a vent. The acoustic insert can include a recess defined by raisedweld regions that are bonded to the interior surface of the housing. Theacoustic insert can further include an aperture that couples the frontvolume to the external environment.

In some embodiments a method of forming an earbud is provided. Themethod can include: forming a housing having an interior surface and anexterior surface; forming an acoustic insert such that it has a recessdefined by raised weld regions; inserting the acoustic insert within thehousing such that the raised weld regions are disposed against theinterior surface of the housing; and directing a laser through thehousing such that it impinges the raised weld regions of the acousticinsert and welds the raised weld regions to the interior surface of thehousing. In some instances the housing can be formed from a plastic thatis substantially transparent to a wavelength of the laser, and theacoustic insert can be formed from a carbon doped plastic that absorbslaser energy.

In some embodiments a case for a pair of wireless earbuds having awireless radio can include: a housing having a first cavity configuredto receive a first earbud in the pair of earbuds and a second cavityconfigured to receive a second earbud in the pair of earbuds; a lidattached to the housing and operable between a closed position where thelid conceals the earbuds within the case and an open position thatallows a user to remove the earbuds from the case; a connectorconfigured to couple to each of the first and second earbuds, theconnector having a first contact positioned in the first cavity and asecond contact positioned in the second cavity; a lid sensor configuredto generate a detect signal when the lid is moved from a closed positionto an open position; and circuitry coupled to the first or secondcontacts and configured to, in response to the detect signal, send oneor more signals to the pair of wireless earbuds to turn ON the wirelessradio and to initiate pairing of the pair of wireless earbuds to anelectronic device. The circuitry can include a processor operativelycoupled to a computer-readable memory that stores instructions that canbe executed by the processor to send the one or more signals. Theconnector can include a first power contact for the first earbud of thepair of wireless earbuds and a second power contact for the secondearbud of the pair of wireless earbuds, and each of the first and secondpower contacts can be configured to transmit both power and data to thefirst earbud and the second earbud, respectively.

In some embodiments a case for a portable listening device that includesa wireless radio can include: a housing having a receiving area for theportable listening device; a lid attached to the housing and operablebetween a closed position where the lid conceals the portable listeningdevice within the case and an open position that allows a user to removethe portable listening device from the receiving area; an electricalconnector positioned within the receiving area, the electrical connectorhaving one or more case electrical contacts that electrically connect tothe one or more device electrical contacts when the portable listeningdevice is received in the receiving area; an input device configured togenerate a signal in response to a user-generated action; and aprocessor coupled to the input device and the electrical connector. Theprocessor can be configured to receive the signal from the input deviceand, in response, send an instruction to the portable listening devicethrough the electrical connector to initiate wireless pairing of theportable listening device to a host electronic device. In some instancesthe processor can be further configured to receive send an instructionto the portable listening device through the electrical connector toturn ON its wireless radio in response to receiving the signal from theinput device prior to sending an instruction to the portable listeningdevice to initiate wireless pairing of the portable listening device tothe host electronic device.

In various embodiments the portable listening device can be a pair(first and second) of wireless earbuds and the electrical connector caninclude a first contact for transmitting power to the first wirelessearbud and a second contact for transmitting power to the secondwireless earbud. Circuitry positioned within the housing can beconfigured to transmit data signals between the case and the first andsecond wireless earbuds over the first and second contacts,respectively, that are also used to charge the earbuds. The input devicecan include one or both of a lid sensor that is activated by a usermoving the lid from the closed position to the open position and adepressible button on the case. In some instances where two or moredifferent input devices are included, such as a lid sensor and adepressible button, the different input devices can generate differentsignals that are distinguishable by the processor and can be used by theprocessor to initiate different pairing procedures. The case can alsoinclude a rechargeable battery that is coupled to one or more caseelectrical contacts within the case that are configured to provideelectrical charge to the first and second wireless earbuds to recharge abatteries within the earbuds.

In some embodiments a method of wirelessly pairing a first electronicdevice to a second electronic device is provided. The method caninclude: receiving an input from a user at a third electronic device,different than the first and second devices. In response to receivingthe input, the third electronic device can communicate a user inputsignal to the first electronic device through a wired connection betweenthe third and the first electronic devices. In response to the firstelectronic device receiving the user input signal, the first electronicdevice can broadcast a wireless pairing request, and in response toreceiving the wireless pairing request, the second electronic device canwirelessly pair with the first device. In some instances, the firstelectronic device can be a wireless headphone set, the second electronicdevice can be a mobile electronic device and the third electronic devicecan be a case for the portable listening device. Also, in someembodiments where the third electronic device is a case for a portablelistening device, the input from the user can be opening a lid of acase.

In some embodiments a case for a pair of earbuds is provided where eachearbud has an ear portion and a stem portion with an electricalconnector disposed at a distal end of the stem portion. The case caninclude: a housing; an insert positioned within the housing, the inserthaving first and second cavities sized and shaped to accommodate firstand second earbuds, respectively, each of the first and second cavitieshaving a receiving opening to receive an earbud into the cavity and acontact opening opposite the receiving opening; and a contact assemblyattached to the insert, the contact assembly comprising a first pair ofelectrical contacts extending into the first cavity and a second pair ofelectrical contacts extending into the second cavity, the first andsecond pairs of electrical contacts configured to make electricalcontact with the electrical connector disposed at the distal end of thefirst and second earbuds, respectively, through the contact opening. Theinsert can include first and second shells joined together, the firstshell including the first cavity and the second shell including thesecond cavity. The case can further include a collar adhered to a top ofthe contact assembly and to a periphery of a distal end of each of thefirst and the second shells. The first and second pairs of electricalcontacts can each have arcuate portions that are positioned by a contactcarrier to couple to the electrical connector disposed at the distal endof the first and second earbuds.

In some embodiments an electrical connector assembly for an earbudcharging system is provided. The electrical connector assembly can beconfigured to receive an earbud having an ear portion and a stem portionwith an earbud connector disposed at a distal end of the stem portion.The electrical connector assembly can include: a shell having areceiving opening to receive the earbud in a stem-first orientation, adistal end opposite the receiving opening, and a contact openingproximate the distal end that opens to the receiving opening; a contactcarrier formed from a dielectric material and coupled to the distal endof the shell, the contact carrier having a cavity sized to receive thedistal end of the shell and a pair of contact receiving slots; and apair of deflectable electrical contacts disposed within the pair ofcontact receiving slots, each deflectable electrical contact having acontact portion that extends through the contact opening of the shell.

In some embodiments a case for a pair of earbuds is provided where eachearbud has an ear interface portion and a stem portion with anelectrical connector disposed at a distal end of the stem portion. Thecase can include: a housing; an insert positioned within the housing,the insert having first and second earbud receiving cavities sized andshaped to accommodate first and second earbuds, respectively, each ofthe first and second receiving cavities having a receiving opening toreceive an earbud into the receiving cavity in a stem-first orientation,a contact opening at an opposite end of the receiving opening; a contactcarrier formed from a dielectric material and coupled to the insert, thecontact carrier having first and second pairs of contact receiving slotsdisposed at a contact interface region and a debris recess configured tocapture debris positioned between the first pair of contact receivingslots and a second debris recess disposed below the contact interfaceregion and sized and shaped to capture debris; a first pair ofdeflectable electrical contacts disposed within first pair of contactreceiving slots, each of the first pair of deflectable electricalcontacts having a contact portion that extends into the first receivingcavity in the contact interface region; and a second pair of deflectableelectrical contacts disposed within second pair of contact receivingslots, each of the second pair of deflectable electrical contacts havinga contact portion that extends into the second receiving cavity in thecontact interface region. In some instance the debris recess can includea first debris recess positioned between the first pair of contactreceiving slots and a second debris recess positioned between the secondpair of contact receiving slots. Each of the first and second earbudreceiving cavities can include an elongated tube portion sized andshaped to accommodate the stem portion of an earbud and a larger earbudreceiving opening sized and shaped to at least partially accommodate theear interface portion. The contact portion of each of the deflectableelectrical contacts can have a curved profile.

In some embodiments a wireless earbud is provided that includes: ahousing having a stem portion aligned with a longitudinal axis, the stemportion including first and second ends; a speaker assembly having adriver unit and a directional sound port proximate the first end andoffset from the longitudinal axis, wherein the driver unit is aligned toemit sound from the directional sound port and comprises a magnet, avoice coil, and a diaphragm; a rechargeable battery disposed in thehousing; and first and second external contacts exposed at an externalsurface at the second end of the stem portion and electrically coupledto provide power to the rechargeable battery. The first and secondexternal contacts can each have a partial annular shape and can bespaced in an oppositional and symmetrical relationship with each other.In some instances an outer perimeter of the first and second externalcontacts is flush with an exterior surface of the stem portion.

In some embodiments a wireless earbud includes: a housing having a stemportion aligned with a longitudinal axis, the stem portion includingfirst and second ends; a speaker assembly having a driver unit and adirectional sound port proximate the first end and offset from thelongitudinal axis, wherein the driver unit is aligned to emit sound fromthe directional sound port and comprises a magnet, a voice coil, and adiaphragm; a rechargeable battery disposed in the housing; a firstsemicircular contact disposed at an external surface at the second endof the stem portion and electrically coupled to the rechargeablebattery; and a second semicircular contact disposed at an externalsurface at the second end of the stem portion, the first and secondpartial annular contacts spaced in an oppositional and symmetricalrelationship with each other.

In some embodiments a wireless earbud includes: a housing; arechargeable battery disposed in the housing; a speaker assemblyincluding a driver unit and a directional sound port, wherein the driverunit is aligned to emit sound from the directional sound port andcomprises a magnet, a voice coil, and a diaphragm; and a plurality ofcontacts exposed at an external surface of the housing, each contact inthe plurality of contacts including a conductive base having a binarymetal alloy plated layer at an outer surface of each contact, the binarymetal alloy plated layer comprising rhodium and ruthenium. In someinstances, the weight percentage of rhodium is at least 85 percent, withthe remainder in ruthenium.

Some embodiments of the disclosure pertain to a case for an earbudhaving one or more earbud magnetic components. The case can include: areceiving cavity sized and shaped to accept the earbud; one or morehousing magnetic components disposed within the case and positioned andconfigured to magnetically attract and magnetically secure the earbudinto the receiving cavity and the second earbud into the secondreceiving cavity; and a lid operable between an open position in whichthe receiving cavity is exposed and a closed position in which the lidcovers the receiving cavity. The case can be configured to store a pairof earbuds and the receiving cavity includes a first receiving cavitysized and shaped to accept a first earbud in the pair of earbuds, and asecond receiving cavity sized and shaped to accept a second earbud inthe pair of earbuds. In some embodiments the one or more housingmagnetic components can include a first plurality of magnetic componentsdisposed around the first receiving cavity and configured tomagnetically attract and magnetically retain the first earbud within thefirst receiving cavity, and a second plurality of magnetic componentsdisposed around the second receiving cavity and configured tomagnetically attract and magnetically retain the second earbud withinthe second receiving cavity.

In some examples the first plurality of magnetic components can includea first magnetic component positioned and configured to magneticallyattract a speaker magnet in the first earbud and the second plurality ofmagnetic components can include a second magnetic component positionedand configured to magnetically attract a speaker magnet in the secondearbud. In other examples the first plurality of magnetic components caninclude a first magnetic component positioned and configured tomagnetically attract a magnetic plate disposed in an ear portion of thefirst earbud and the second plurality of magnetic components can includea second magnetic component positioned and configured to magneticallyattract a magnetic plate disposed in an ear portion of the secondearbud.

In some instances the first plurality of magnetic components canincludes one or more magnetic components disposed around a portion ofthe first receiving cavity that accepts an ear interface portion of thefirst earbud and the second plurality of magnetic components can includeone or more magnetic components disposed around a portion of the secondreceiving cavity that accepts an ear interface portion of the secondearbud. In some instances the first plurality of magnetic components caninclude a first housing magnetic component arranged to attract a speakermagnet in the first earbud, and a second housing magnetic componentarranged to attract a magnetic plate disposed within an ear portion ofthe first earbud; and the second plurality of magnetic components caninclude a third housing magnetic component arranged to attract a speakermagnet in the second earbud, and a fourth housing magnetic componentarranged to attract a magnetic plate disposed within an ear portion ofthe second earbud. In some instances the first plurality of magneticcomponents includes a first set of magnetic components that form a firstHalbach array to increase attractive forces for the first earbud and thesecond plurality of magnetic components includes a second set ofmagnetic components that form a second Halbach array to increaseattractive forces for the second earbud. The first and second Halbacharrays can be configured to attract the first and the second earbudsinto respective cavities and magnetically retain them within thecavities until they are removed by a user.

In some embodiments an earbud includes: a housing formed to fit at leastpartially within a user's ear; a directional sound port formed withinthe housing; a speaker assembly disposed within the housing andincluding a driver unit comprising a first magnet, the driver unitaligned to emit sound from the directional sound port; a magneticretention component, separate from the speaker assembly, and positionedin the housing. The housing can have an ear portion and a stem portion,and the magnetic retention component can be disposed within the earportion. The driver unit can include a diaphragm and a voice coil, andthe first magnet can be operatively coupled to the voice coil to movethe diaphragm in response to electrical signals and the magneticretention component is not operatively coupled to the voice coil.

In some embodiments a wireless listening system is provided thatincludes a pair of wireless earbuds and a storage case for the pair ofearbuds. Each wireless earbud can include: a housing formed to fit atleast partially within a user's ear; a directional sound port formedwithin the housing; a speaker assembly disposed within the housing andincluding a driver unit comprising a first magnet, a diaphragm and avoice coil, and wherein the first magnet is operatively coupled to thevoice coil to move the diaphragm in response to electrical signals, thedriver unit aligned to emit sound from the directional sound port; and amagnetic retention component, separate from the speaker assembly, andpositioned in the housing. The storage case can include: a firstreceiving cavity sized and shaped to accept a first earbud of the pairof earbuds; a second receiving cavity sized and shaped to accept asecond earbud of the pair of earbuds; a plurality of housing magneticcomponents disposed within the case and positioned and configured tomagnetically attract and magnetically secure the first earbud into thefirst receiving cavity and the second earbud into the second receivingcavity; and a lid operable between an open position in which the firstand second receiving cavities are exposed and a closed position in whichthe lid covers the first and second receiving cavities. The plurality ofhousing magnetic components can include a first magnetic componentpositioned and configured to magnetically attract a speaker magnet inthe first earbud and a second magnetic component positioned andconfigured to magnetically attract a speaker magnet in the secondearbud. The plurality of housing magnetic components can furtherincludes a third magnetic component positioned and configured tomagnetically attract a magnetic plate disposed in an ear portion of thefirst earbud and a fourth magnetic component positioned and configuredto magnetically attract a magnetic plate disposed in an ear portion ofthe second earbud.

In some embodiments a case for a portable listening device includes: ahousing having one or more cavities configured to receive the portablelistening device and an exterior charging surface; a lid attached to thehousing and operable between a closed position where the lid is alignedover the one or more cavities and an open position where the lid isdisplaced from the one or more cavities; a battery; a first chargingsystem configured to charge the portable listening device whenpositioned in the one or more cavities; and a second charging systemincluding a transmitting coil positioned within the housing adjacent tothe exterior charging surface, the transmitting coil configured towirelessly transmit power to a power receiving coil of an electronicdevice positioned outside the housing adjacent to the exterior chargingsurface. In some embodiments the portable listening device can be a casefor a pair of earbuds; the housing can include first and second cavitiesconfigured to receive first and second earbuds, respectively; and thefirst charging system can be configured to charge the first and secondearbuds when the earbuds are positioned within the first and secondcavities.

In some embodiments a case for a pair of earbuds is provided. Eachearbud can include an ear interface portion, a stem, an earbud batteryand a wireless radio. The case include: a housing having a first cavityconfigured to receive a first earbud in the pair of earbuds and a secondcavity configured to receive a second earbud in the pair of earbuds; alid operable between a closed position where the lid conceals the pairof earbuds within the case and an open position where the lid isdisplaced from the case such that a user can remove the earbuds from thecase and first and second charging systems. The first charging systemcan include: a case battery; a wireless power receiving coil positionedwithin the housing, the wireless power receiving coil configured towirelessly receive power from a wireless power source; a connectorconfigured to couple to each of the first and second earbuds, the secondconnector having at least one contact positioned in the first cavity andat least one contact positioned in the second cavity; and chargingcircuitry operatively coupled to charge the case battery and providepower to the connector to charge the first and second earbuds fromwireless power received over the wireless power receiving coil. Thesecond charging system can include a transmitting coil positioned withinthe housing and configured to wirelessly transmit power to a powerreceiving coil of an auxiliary electronic device positioned adjacent thecase. The case can further include an earbud detector configured todetect when an earbud is placed in either of the first or secondcavities.

In some embodiments an electrical receptacle connector is disclosed thatincludes: a housing comprised of an electrically insulative polymer thatextends between a receiving face and a rear face, the housing defining acavity that communicates with an opening in the receiving face toreceive a plug portion of a mating plug connector; a contact spacerpositioned adjacent to the rear face; a gasket disposed between the rearface of the housing and the contact assembly; a plurality of contacts,each of the plurality of contacts having a tip positioned within thecavity, an anchor portion that anchors each contact to the contactspacer and a beam portion that connects the tip to the anchor portion;and a metallic bracket disposed around an outside surface of thehousing.

In some other embodiments an electrical receptacle connector includes: ahousing comprised of an electrically insulative polymer that extendsbetween a receiving face and a rear face, the housing defining a cavitythat communicates with a front opening in the receiving face to receivea plug portion of a mating plug connector and wherein the housing has aplurality of slots that form a portion of the cavity; a contact assemblyincluding: (i) a contact spacer positioned adjacent to the rear face;(ii) a plurality of contacts, each of the plurality of contacts having atip that extents into the cavity through one of the plurality of slots,an anchor portion coupled to the contact spacer, and a beam portion thatconnects the tip to the anchor portion; and (iii) a ground latch havingfirst and second spring arms on opposing sides of the plurality ofcontacts; a gasket disposed between the rear face of the housing and thecontact assembly; and a metallic bracket disposed around an outsidesurface of the housing and formed to secure the contact assembly to thehousing.

Some embodiments pertain to an earbud including: a housing defining acavity in which one or more electrical components of the earbud arehoused, the housing having a touch sensitive region at an exteriorsurface of the housing and an interior surface within the cavityopposite the exterior surface; a capacitive sensor insert having a firstsurface with metallized circuitry formed thereon and positioned withinthe housing such that the first surface is adjacent the interior surfaceof the housing; an earbud processor disposed within the housing; and atleast one conductor that electrically couples the capacitive sensorinsert to the earbud processor. The capacitive sensor insert can beformed to closely match a shape of the housing. In some instances themetallized circuitry forms at least one self-capacitance sensor inwhich, when touched by a user, loads self-capacitance circuitry that canbe detected. In other instances the metallized circuitry includes rowand column electrodes that form at least one mutual-capacitance sensorin which, when touched by a user, mutual coupling between row and columnelectrodes is altered and detected. The capacitive sensor insert isformed from a plastic that includes metallic particulates.

In some embodiments an earbud includes: a housing that defines anenclosed cavity in which one or more electrical components of the earbudare housed, the earbud housing having a touch sensitive region at anexterior curved surface of the housing and an interior curved surfacewithin the enclosed cavity opposite the exterior curved surface; adirectional sound port formed within the housing; a speaker assemblydisposed within the enclosed cavity and including a driver unitcomprising a magnet, the driver unit aligned to emit sound from thedirectional sound port; a capacitive sensor configured to sense a user'stouch on the touch sensitive region, the capacitive sensor including asensor insert positioned within the enclosed cavity and one or moreacoustic apertures aligned with the directional sound port, the sensorinsert having a first surface adjacent to and contoured to match theinterior curved surface, the first surface including metallizedcircuitry formed thereon and at least partially surrounding the acousticaperture; and a processor coupled to the capacitive sensor and disposedwithin the enclosed cavity.

In some embodiments a case for a listening device includes: a housinghaving a cavity to receive the listening device; a lid attached to thehousing with a pivotable joint allowing the lid to rotate between aclosed position where the lid is aligned over the cavity and an openposition where the lid is angularly displaced allowing the listeningdevice to be removed from the cavity; and an over center mechanism forthe lid including an extension attached to the lid and disposed on anopposite side of the pivotable joint from the lid, wherein the extensionis in contact with an arm that resists the lid rotating from the openposition to the closed position until the lid is moved past an overcenter position when the lid is then impelled to the closed position.

In some embodiments a case for an electronic device includes: a housinghaving a cavity to receive the electronic device and a receiving openingthat communicates with the receiving opening; a lid secured to housingwith a first pivotable joint, the lid being operable between an openposition in which the receiving opening is exposed and a closed positionin which the lid covers the receiving opening; and a spring loaded overcenter mechanism for the lid. The spring-loaded over-center mechanismcan include: an extension coupled to the lid and having a roundedcontact portion at a distal end; an arm coupled to the housing by asecond pivotable joint, the arm extending between a first end attachedto the second pivotable joint and a second end, opposite the first end,the arm having first and second surfaces extending between the first andsecond ends; and a torsion spring formed around the second pivotablejoint such that it applies a torque to the arm forcing the arm againstthe rounded portion of the extension.

To better understand the nature and advantages of the presentdisclosure, reference should be made to the following description andthe accompanying figures. It is to be understood, however, that each ofthe figures is provided for the purpose of illustration only and is notintended as a definition of the limits of the scope of the presentdisclosure. Also, as a general rule, and unless it is evident to thecontrary from the description, where elements in different figures useidentical reference numbers, the elements are generally either identicalor at least similar in function or purpose.

To better understand the nature and advantages of the presentdisclosure, reference should be made to the following description andthe accompanying figures. It is to be understood, however, that each ofthe figures is provided for the purpose of illustration only and is notintended as a definition of the limits of the scope of the presentdisclosure. Also, as a general rule, and unless it is evident to thecontrary from the description, where elements in different figures useidentical reference numbers, the elements are generally either identicalor at least similar in function or purpose.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a case having a lid and configured to hold apair of earbuds according to embodiments of the disclosure;

FIG. 2 is a system level diagram of a case with a charging systemcoupled to a pair of earbuds according to some embodiments of thedisclosure;

FIG. 3 is a simplified cross-sectional view of the case shown in FIG. 1;

FIG. 4A is a partial cross-sectional view of an earbud connectoraccording to an embodiment of the disclosure;

FIG. 4B is a plan view of the earbud connector illustrated in FIG. 4A;

FIG. 5A is a partial cross-sectional view of another embodiment of anearbud connector according to the disclosure;

FIG. 5B is a plan view of the earbud connector illustrated in FIG. 5A;

FIG. 6A is a partial cross-sectional view of another embodiment of anearbud connector according to the disclosure;

FIG. 6B is a plan view of the earbud connector illustrated in FIG. 6A;

FIG. 6C is an isometric exploded view of a connector assembly for theearbud connector illustrated in FIG. 6A;

FIG. 6D is an isometric view of the assembled earbud connectorillustrated in FIG. 6A;

FIG. 7A is an isometric exploded view of another embodiment of an earbudconnector according to the disclosure;

FIG. 7B is an isometric view of the assembled earbud connectorillustrated in FIG. 7A;

FIG. 8A is a partial cross-sectional view of another embodiment of anearbud connector according to the disclosure;

FIG. 8B is a plan view of the connector on the earbud illustrated inFIG. 8A;

FIG. 8C is an isometric exploded view of the earbud connectorillustrated in FIG. 8A;

FIGS. 9A and 9B are front and rear isometric views of one of the earbudsshown in FIG. 1, respectively;

FIG. 10 is a top view of the case shown in FIG. 1 with the case lidremoved;

FIG. 11 is a partial cross-sectional view of an earbud retained in acavity within the case illustrated in FIG. 10 along section A-A;

FIG. 12 is a partial cross-sectional view of an earbud retained in acavity within the case illustrated in FIG. 10 along section B-B;

FIG. 13 is an isometric view of a case having an over center lidaccording to some embodiments of the disclosure;

FIG. 14 is an isometric view of the case shown in FIG. 13 with the overcenter lid in an open position;

FIG. 15 is a graph showing attraction and repulsion forces associatedwith an over center lid according to some embodiments of the disclosure;

FIG. 16 is a side view of a case that includes one pair of magnets withmisaligned poles and one pair with a high permeable material surroundingthem according to some embodiments of the disclosure;

FIG. 17 is a side view of a case that includes two pairs of magnetsattached to springs according to some embodiments of the disclosure;

FIG. 18 is an isometric view of a magnet that may be used in a caseaccording to some embodiments of the disclosure;

FIG. 19 is an isometric view of a magnet that may be used in a caseaccording to some embodiments of the disclosure;

FIG. 20 is an isometric view of a magnet that may be used in a caseaccording to some embodiments of the disclosure;

FIG. 21 is an isometric view of a magnet that may be used in a caseaccording to some embodiments of the disclosure;

FIG. 22A is a side view of a case with a torsion spring over centermechanism according to some embodiments of the disclosure with its lidclosed;

FIG. 22B is an isometric view of the torsion spring over centermechanism illustrated in FIG. 22A;

FIG. 22C is a side view of the case illustrated in FIG. 22A with its lidpartially open;

FIG. 22D is a side view of the case illustrated in FIG. 22A with its lidopen further;

FIG. 23 is a simplified perspective view of a wireless charging systemaccording to embodiments of the disclosure;

FIG. 24 is a block diagram of an inductive power receiving system thatcan be part of the charging system illustrated in FIG. 23 according tosome embodiments;

FIG. 25 is a simplified plan view of the earbud case illustrated in FIG.23;

FIG. 26 is a block diagram of an embodiment of the inductive powertransmitting system illustrated in FIG. 23;

FIG. 27 is a simplified isometric view of an inductively charged case onan inductive charging system according to some embodiments of thedisclosure;

FIG. 28 is an isometric view of an electrical connector that can beincluded in the case illustrated in FIG. 1 according to some embodimentsof the disclosure;

FIG. 29 is an isometric exploded view of the electrical connectorillustrated in FIG. 28;

FIG. 30 illustrates isometric front and rear views of a left earbudaccording to some embodiments of the disclosure;

FIG. 31 illustrates isometric front and rear views of a right earbudaccording to some embodiments of the disclosure;

FIG. 32 is a cross-sectional view of one of the earbuds illustrated inFIGS. 30 and 31;

FIG. 33 is a cross-sectional view of one of the earbuds illustrated inFIGS. 30 and 31 with some components removed;

FIG. 34 is a plan view of a flexible circuit board that can be used inearbuds according to some embodiments of the disclosure;

FIG. 35 is an isometric view of the flexible circuit board illustratedin FIG. 34;

FIG. 36 is an isometric view of a connector structure that can beincluded in the earbuds illustrated in FIGS. 30 and 31;

FIG. 37 is an isometric view of contacts for the connector structureillustrated in FIG. 36 according to some embodiments of the disclosure;

FIG. 38 is an isometric view of the contact structure illustrated inFIG. 36;

FIG. 39 is an isometric view of an earbud connector contact according toan embodiment of the disclosure;

FIG. 40 is an isometric view of an insert molded connector contact thatwas illustrated in FIG. 39;

FIG. 41 is an isometric view of an earbud with a capacitive sensorinsert according to some embodiments of the disclosure;

FIG. 42 is a cross-section of the earbud and the capacitive sensorinsert illustrated in FIG. 41;

FIG. 43 is a plan view of a capacitive sensor insert illustratedaccording to an embodiment of the disclosure;

FIG. 44 is a plan view of a capacitive sensor insert illustratedaccording to an embodiment of the disclosure;

FIG. 45A is an illustration of an earbud with an acoustic insertaccording to an embodiment of the disclosure;

FIG. 45B is an illustration of the earbud with the acoustic insertillustrated in FIG. 45A;

FIG. 46 is a flowchart illustrating steps associated with manufacturingan earbud according to some embodiments of the disclosure;

FIG. 47 illustrates a system 47 according to some embodiments of thedisclosure;

FIG. 48 is a simplified block diagram of a system 4800 according to someembodiments of the disclosure;

FIG. 49 is a flowchart illustrating steps associated with pairingwireless headphones with a host device according to some embodiments ofthe disclosure;

FIG. 50 is a flowchart illustrating steps associated with activating awireless radio in earbuds according to some embodiments of thedisclosure; and

FIG. 51 is a flowchart illustrating steps associated with deactivating awireless radio in earbuds according to some embodiments of thedisclosure.

DETAILED DESCRIPTION

Some embodiments of the present disclosure relate to portable listeningdevices and cases for containing and/or charging such devices that haveimproved features that can improve the user experience associated withusing the case and/or the portable listening device. While the presentdisclosure can be useful for a wide variety of portable listeningdevices, some embodiments of the disclosure are particularly useful forwireless earbuds and cases for wireless earbuds as described in moredetail below.

For example, in some embodiments a pair of wireless earbuds are sizedand shaped to fit within a case that can also include a rechargeablebattery and charging circuitry. The pair of earbuds can be charged whenan earbud detector within the case detects that the earbuds are placedwithin the case. Further the case can include sensors to detect if thelid is open such that the wireless radio within each earbud can beactivated so they are ready for use by the user. Similarly, when the lidis closed the wireless radio can be shut off so the charge in the earbudbatteries is conserved.

In another example the case can have a pairing button on it that isoperable to place the earbuds in a pairing mode. In a further examplethe case can also have one or more charge indicator lights to inform theuser of the charge level in the case battery as well as the charge levelin each earbud.

In another example the case can have a lid with an over centerconfiguration such that the lid is in a first stable position when in aclosed position and is in a second stable position when in the openposition, but is in an unstable position in-between the closed positionand the open position. In some embodiments the over center configurationcan be achieved by using two pairs of magnets while in other embodimentsit can be achieved with a torsion spring. In further examples the casecan have one or more magnets within it to attract the earbuds intocavities formed within the case and to retain them until a user removesthem.

In another example the case can be liquid-tight to prevent liquid fromdamaging the internal circuitry. The electrical connections for both theearbud recharging and for recharging the case can be resistant topenetration by a liquid.

In another example the earbuds can have an acoustic insert that formsone or more acoustic ports such as a bass port vent and a rear vent thatenable the internal speaker to provide audio performance in the confinedspace within the earbud housing.

In another example the earbud case can be used to initiate Bluetooth®pairing of the earbuds with a host device. In one embodiment a lidposition sensor detects when the lid is open and initiates pairing ofthe earbuds.

In order to better appreciate the features and aspects of portablelistening devices and their cases according to the present disclosure,further context for the disclosure is provided in the following sectionby discussing several particular implementations for earbuds and a casefor earbuds according to embodiments of the present disclosure. Thespecific embodiments discussed are for example purposes only and otherembodiments can be employed in other portable listening devices andcases that can be used for other portable listening devices as well asother devices.

As used herein, the term “portable listening device” includes anyportable device designed to play sound that can be heard by a user.Headphones are one type of portable listening device, portable speakersare another. The term “headphones” represents a pair of small, portablelistening devices that are designed to be worn on or around a user'shead. They convert an electrical signal to a corresponding sound thatcan be heard by the user. Headphones include traditional headphones thatare worn over a user's head and include left and right listening devicesconnected to each other by a headband, headsets (a combination of aheadphone and a microphone); and earbuds (very small headphones that aredesigned to be fitted directly in a user's ear). Traditional headphonesinclude both over-ear headphones (sometimes referred to as eithercircumaural or full-size headphones) that have earpads that fullyencompass a user's ears, and on-ear headphones (sometimes referred to assupra-aural headphones) that have earpads that press against a user'sear instead of surrounding the ear. As used herein, the term “earbuds”,which can also be referred to as earphones or ear-fitting headphones,includes both small headphones that fit within a user's outer ear facingthe ear canal without being inserted into the ear canal, and in-earheadphones, sometimes referred to as canalphones, that are inserted inthe ear canal itself.

Earbud Case

FIG. 1 depicts a simplified plan view of a case 100 for a pair ofwireless earbuds according to some embodiments of the disclosure. Asshown in FIG. 1, case 100 includes a housing 105, also called a body,having one or more cavities 110 a, 110 b configured to receive a pair ofearbuds 115 a, 115 b. In some embodiments, cavities 110 a, 110 b can bepositioned adjacent to each other on opposite sides of a center plane ofcase 100. Each cavity 110 a, 110 b can be sized and shaped to match thatof its respective earbud 115 a, 115 b. Each cavity can include a stemsection 116 a, 116 b and a bud section 117 a, 117 b. Each stem section116 a, 116 b can be an elongated generally cylindrical cavity thatextends from its respective bud section 117 a, 117 b towards a bottom106 of case 100. Each bud section 117 a, 117 b can be offset from itsrespective stem section 116 a, 116 b and open at an upper surface 108 ofhousing 105. Embodiments of the disclosure are not limited to anyparticular shape, configuration or number of cavities 110 a, 110 b andin other embodiments cavities 110 a, 110 b can have different shapes toaccommodate different types of earbuds, different configurations and/orcan be a single cavity or more than two cavities.

Case 100 further includes a lid 120 attached to housing 105. Lid 120 isoperable between a closed position where lid 120 is aligned over one ormore cavities 110 a, 110 b fully enclosing pair of earbuds 115 a, 115 bwithin the housing, and an open position where the lid is displaced fromthe housing and cavities 110 a, 110 b such that a user can remove theearbuds from the cavities or replace the earbuds within the cavities.Lid 120 can be pivotably attached to housing 105 and can include amagnetic or mechanical system (not shown in FIG. 1) that provides lid120 with a bi-stable operation, as described more fully below. In someembodiments case 100 can also include a charging system 125 configuredto charge pair of earbuds 115 a, 115 b; one or more magnets 130configured to orient and retain the pair of earbuds within one or morecavities 110 a, 110 b; and other features that are further describedbelow.

FIG. 2 is a simplified block diagram of system 200 according to anembodiment of the present disclosure. System 200 can include pair ofearbuds 202 a, 202 b, a case 204 for the pair of earbuds, and a powersource 205 for charging the case. Earbuds 202 a, 202 b can be positionedwithin case 204 (e.g., within an interior space or cavity of the casedefined by a housing or an insert within the housing) where they can beconveniently stored and charged. Case 204 can be representative of case100 and earbuds 202 a, 202 b can be representative of earbuds 115 a, 115b discussed above with respect to FIG. 1.

Each earbud 202 a, 202 b can each have one or more inputs 255, internalcomponents 260 and one or more outputs 265. In some embodiments one ormore inputs 255 can be a microphone input and one or more buttons orsensors that register a user's touch. In various embodiments anaccelerometer or a capacitive sensor can be used as an input 255 and canbe activated, for example, by a user to answer a call or command earbuds202 a, 202 b to enter a pairing mode that can be indicated by a light oneither or both earbuds. In various embodiments one or more internalcomponents 260 can include a speaker, a microphone, a rechargeablebattery, a processor, and/or other circuitry and components. In variousembodiments one or more outputs 265 can be audio from a speaker, a lightor other indicator. In some embodiments the indicator light can indicatean incoming call, a battery charge level, a pairing mode or otherfunction.

In some embodiments each of earbuds 202 a, 202 b can include a wirelessradio that can be both an input 255 and an output 265 device. Thewireless radio can enable the earbuds to receive an audio signal from anaudio player, such as a smart phone. In some embodiments one or more ofearbuds 202 a, 202 b include a radio that can also transmit an audiosignal such as a microphone signal from one or more of the earbuds. Inyet further embodiments, one or more of earbuds 202 a, 202 b can includea radio that can transmit communication signals that can command thereceiving device (e.g., a host device such as a smartphone) to performone or more functions such as, but not limited to, connect a phone call,disconnect a phone call, pause audio playback, fast forward or rewindaudio playback or mute a microphone signal. The wireless radio canemploy any short range, low power communication protocol such asBluetooth®, low power Bluetooth®, or Zigbee among protocols.

Case 204 can include a case processor 210, an earbud detector 215, radio217, a lid sensor 220, case charging circuitry 225, a battery 227 andearbud charging circuitry 230. Case 204 can also include an earbudinterface 245 that enables circuitry within case 204 to communicate withand/or charge earbuds 202 a, 202 b and power source interface 250 thatcouples the case to wired or wireless power source 205, such as an AC orDC power source or an inductive charging pad. In some embodiments, casecharging circuitry 225, battery 227, earbud charging circuitry 230 andinterfaces 245 and 250 are all representative components of chargingsystem 125 shown in FIG. 1.

Power source interface 250 can be part of a receptacle connector for amicro USB connector, a Lightening connector or other connector that canprovide power to earbud case 204. Alternatively, or in addition to areceptacle connector, power interface 250 can include a wireless powerreceiver, such as one or more wireless power receiving coils, that canreceive inductive power from power source 205. Earbud interface 245 cantransfer power and/or data between case 204 and the earbuds via casetransfer interface 270 in each earbud. Earbud interface 245 can includean electrical connector, such as one of the connectors described hereinwith respect to FIGS. 4A-8C, a different type of electrical connector,or a wireless power transmitter, such as a wireless power transmittingcoil that can transmit inductive power to an inductive power receiverwithin the earbuds.

Case processor 210 can be configured to control various functions ofcase 204 as described in more detail below. In some embodiments, earbuddetector 215 includes one or more sensors that detect when one or bothof earbuds 202 a, 202 b are placed within case 204. In one embodimentearbud detector 215 can be a circuit that periodically “pings” theearbud contacts within case 204 to determine if either earbud 202 a, 202b is present. In other embodiments earbud detector 215 can be any typeof mechanical or electrical sensor, such as, but not limited to, amagnetic sensor, an optical sensor, a switch, a hall effect sensor, aflux sensor, a capacitive sensor, a photodetector, a proximity detector,a momentary switch or any other type of sensor.

In embodiments where earbud detector 215 is a flux sensor, the fluxsensor can be beneficial to minimizing power consumption of case 204. Asan example, a flux sensor can be formed in case 204 for each earbud froma coil of wire and one or more magnets within earbuds 202 a, 202 b. Eachflux sensor can be configured to generate a current in the coil of wirewhen an earbud is inserted or withdrawn from case 204 and the magnetwithin the earbud passes through the coil of wire. In a further example,a flux sensor can function as a completely passive sensor that requiresno power to operate, and generates its own energy to notify processor210 of the removal or replacement of either earbud 202 a, 202 b withincase 204. In some embodiments a hall effect sensor can also bebeneficial to minimize power consumption. In various embodiments, one ormore sensors can be beneficial so that a voltage bias (e.g., a ping)need not be applied to the earbud connectors, thus mitigating contactcorrosion and/or oxidation in moist environments.

In one example case 204 can include separate earbud receiving cavitieswithin the case, such as cavities 110 a, 110 b described above, andearbud detector 215 can include first and second earbud detectors—onedetector for each cavity. The first earbud detector can be operativelycoupled to detect when an earbud (e.g., a left earbud) is insertedwithin a first of the cavities and the second earbud detector can beoperatively coupled to detect when an earbud (e.g., a right earbud) isinserted within the other cavity. In other embodiments a single detectorcan detect when either earbud 202 a, 202 b is placed within case 204.

In response to detecting the insertion of an earbud within the case,earbud detector 215 can generate a detect signal that can be sent to andprocessed by other circuitry within case 204 to initiate charging of thebuds. When earbud detector 215 includes first and second detectors thatcan detect the insertion of the left and right earbuds (or first andsecond earbuds that are interchangeable between the left and rightears), respectively, each earbud detector can generate a separate detectsignal that can initiate charging of the detected earbud only.

Similar to initiating charging, earbud detector 215 can also be used tostop charging. For example, earbud detector 215 can detect when eitheror both of the earbuds are removed from the case and generate a removalsignal that stops the charging of the removed earbud or earbuds.

In some embodiments earbud detector 215 can initiate the chargingprocess of each earbud 202 a, 202 b when the earbud detector detectsthat electrical contact is made between the earbuds and correspondingcharging contacts within the housing (e.g., within each cavity 110 a,110 b). More specifically, in various embodiments earbud detector 215can periodically “ping” the charging contacts to see if either or bothearbuds 202 a, 202 b are present within each cavity 110 a, 110 b. Evenif either or both earbuds 202 a, 202 b have zero battery charge they canstill have a characteristic impedance or other electrical characteristicthat enables earbud detector 215 to detect that they are connected tothe charging contacts and initiate charging with earbud chargingcircuitry 230. The charging contacts and electrical connection betweenearbuds 202 a, 202 b and case 204 will be discussed in detail below. Insome embodiments earbud detector 215 is part of processor 210 and theprocessor does the sensing. In other embodiments, earbud detector 215 isseparate active/passive components. In various embodiments, case 204does not include a case processor 210 and instead, circuitry comprisingvarious active and/or passive components is configured to perform thefunctions described herein and attributed to the processor.

In some embodiments case processor 210 can communicate with pair ofearbuds 202 a, 202 b by sending and receiving data through earbudinterface 245 (and through case interface of either or both earbuds) andcan communicate with power source 205 by sending and receiving datathrough power source interface 250. That is, in various embodimentsearbud interface 245 and power source interface 250 can be capable ofcarrying both power and data signals for single or bidirectionalcommunication. In some embodiments separate power and data contacts canbe used while in various embodiments one set of contacts is used forboth power and data. For example, in some embodiments power source 205can be a computing device that communicates with power source interface250 through an interface (not shown), such as a USB interconnect or aLightning interconnect developed by Apple Inc. The interconnect canprovide DC current to case battery 227 for charging and can providebidirectional communication between case processor 210 and the computingdevice. In another example power source 205 can transmit firmwareupdates to both case processor 210 and pair of earbuds 202 a, 202 bthrough the same contacts that are used to charge the devices. Datacommunication between earbud interface 245 and pair of earbuds 202 a,202 b can use a similar communication protocol as discussed above or anyother protocol such as, for example, serial communications.

In some embodiments case 204 can include a wireless radio 217 thatenables the case to transmit and receive data communications withearbuds 202 a, 202 b and a host device (e.g., a smartphone, a tabletcomputer, a laptop computer or the like) in addition to, or instead of,relying on data exchange through interfaces 245 and 250. For example,wireless radio 217 can be used to initiate a pairing sequence betweenearbuds 202 a, 202 b and a host device. In another example radio 217 canbe used to receive a music download from a host device to be stored incase 204.

Lid sensor 220 can detect when a lid to the case (e.g., lid 120 shown inFIG. 1) is in the open position and when the lid is in the closedposition. In some embodiments case processor 210 is coupled to lidsensor 220 and receives signals from the lid sensor indicating when thelid is opened and closed. More specifically, in some embodiments lidsensor 220 can generate and send an “open” signal to processor 210 upondetecting when the lid is opened, and lid sensor 220 can generate andsend a “closed” signal to processor 210 upon detecting the closure ofthe lid. Processor 210 can be configured to communicate with pair ofearbuds 202 a, 202 b to turn ON their wireless radios when the lid is inthe open position (e.g., in response to receiving the “open” signal) sothey are ready for use by a user and turn OFF their wireless radios whenthe lid is in the closed position (e.g., in response to receiving the“closed” signal) to conserve their power. In various embodiments lidsensor 220 can also trigger case processor 210 to enter a pairing modewhen the case lid is opened, as explained in more detail below. In someembodiments case processor 210 can communicate with pair of earbuds 202a, 202 b through earbud interface 245 and case interface 270 using awired connection as discussed above, while in other embodiments caseprocessor 210 can communicate with earbuds 202 a, 202 b throughinterfaces 245 and 270 wirelessly in addition to, or instead of, using awired connection. In some embodiments lid sensor 220 can be any type ofmechanical or electrical switch including, but not limited to, amomentary switch, a capacitive sensor, a magnetic sensor (e.g., halleffect) or an optical sensor.

Case battery 227 provides power for the circuitry associated with case204 and can be a rechargeable battery that can be charged by powersource 205 and enclosure charging circuitry 225 through power sourceinterface 250. Case battery 227 is also coupled to earbud interface 245and can charge pair of earbuds 202 a, 202 b in conjunction with earbudcharging circuitry 230. In some embodiments earbud charging circuitry230 can charge pair of earbuds 202 a, 202 b anytime they are properlystored within cavities 110 a, 110 b even though case 204 is not coupledto power source 205. Thus, case 204 can be capable of charging pair ofearbuds 202 a, 202 b while the case is, for example, in a user's pocketas long as case battery 227 has sufficient charge. In variousembodiments case battery 227 can be sealed within case 204, while insome embodiments the case battery can be removable for servicing and/orreplacement with another charged battery. Case processor 210 canadditionally be coupled to case charging circuitry 225 that can controlthe charging of case battery 227 (e.g., control the voltage and currentsupplied to the battery to optimize the speed of charging and the lifeof the battery). In some embodiments case charging circuitry 225 caninclude a DC/DC converter, an AC/DC converter, battery voltage levelmonitoring circuitry and/or safety features to properly charge casebattery 227.

Similarly, in some embodiments case processor 210 can be coupled toearbud charging circuitry 230 that can control the charging of batterieswithin pair of earbuds 202 a, 202 b (e.g., control the voltage andcurrent supplied to the batteries to optimize the speed of charging andthe life of the batteries) through earbud interface 245. In variousembodiments earbud charging circuitry 230 can include a DC/DC converter,battery voltage level monitoring circuitry and/or safety features toproperly charge earbud batteries.

In various embodiments case 204 can include one or more chargeindicators 235 that can indicate a charge level of case battery 227and/or the pair of earbud batteries such that a user can see theindicators on an outer surface of case 100 (see FIG. 1). In someembodiments charge indicators 235 can include three LEDs, one indicatingthe status for case battery 227 and one for indicating the status of thebattery in each of pair of earbuds 202 a, 202 b. In various embodimentscharge indicators 235 can be a first color (e.g., green) if therespective battery is near full charge, a second color (e.g., amber) ifthe respective battery is less than 75 percent charged and a third color(e.g., red) if there is no charge or limited charge. In someembodiments, charge indicators 235 can include multiple LEDs for each ofbattery 227, earbud 115 a and earbud 115 b, where the number of LEDs litindicate the strength of the battery for each component. For example, inone particular instance three sets of three LEDs can be included on case204.

In some embodiments case 204 can also include one or more user inputdevices 240. Each included input device 240 can be a button or othertype of input that, in response to being activated by or otherwisereceiving input from a user, generates a signal that can be communicatedto processor 210 or other circuitry within case 204. Processor 210, orthe other circuitry, can then act upon the signal. For example, invarious embodiments the wireless radios used by pair of earbuds 202 a,202 b can be a Bluetooth® or other radio system that requires a pairingsequence to establish communication between the pair of earbuds and awireless transmitter in an electronic device. In such embodiments, ifinput device 240 is a wireless pairing button, processor 210 can send asignal to the earbuds via earbud interface 245 to place the wirelessradios within pair of earbuds 202 a, 202 b into a pairing mode. Morespecifically, in some embodiments the user can depress a pairing buttonlocated on case 204 that notifies case processor 210 to instruct pair ofearbuds 202 a, 202 b via interface 245 to enter a pairing mode. In someembodiments pair of earbuds 202 a, 202 b can be required to be withinthe case (e.g., within cavities 110 a, 110 b as shown in FIG. 1) whileentering the pairing mode while in other embodiments the earbuds may notneed to be within case 204 and only need to be within wirelesscommunication range of the case. Further details with regard to wirelesspairing will be discussed later in the application.

Now referring to FIG. 3, a simplified cross-sectional perspective viewof case 100 is illustrated. As shown in FIG. 3, case 100 includeshousing 105 having cavities 110 a, 110 b for holding pair of earbuds 115a, 115 b and various electronic circuitry. Case 100 further includes lid120 attached to housing 105 and operable between a closed position wherelid 120 is aligned over one or more cavities 110 a, 110 b fullyenclosing pair of earbuds 115 a, 115 b within housing and an openposition where the cavities 110 a, 110 b are exposed such that a usercan remove or replace the earbuds within the cavities.

As discussed above, lid 120 can be pivotably attached to housing 105with joint 305 enabling the lid to be operable between a closed positionand an open position. In some embodiments lid 120 can have a bi-stableposition where it is stable in the closed and open positions, butunstable between those positions such that it tends to be attracted toeither the closed or the open position. In various embodiments thebi-stable operation can be enabled by employing a first pair of magneticelements 310 a, 310 b and a second pair of magnetic elements 315 a, 315b, as discussed in more detail below. In some embodiments a lid sensor220 can be disposed in housing 105 and configured to detect when lid 120is in the closed position (e.g., when a detectable medium 320 isadjacent the lid sensor) and when the lid is in the open position (e.g.,when the detectable medium is not adjacent the lid sensor). In someembodiments the detectable medium can be a magnetic material.

Pair of earbuds 115 a, 115 b can fit within cavities 110 a, 110 b eachof which is sized and shaped to accept one of the earbuds. In someembodiments, when each earbud is fully inserted within its respectivecavity 110 a, 110 b, a portion of each earbud extends out of the cavityenabling a user to easily grab and remove the earbud from the case. Lid120 can include a cavity (or pair of cavities 360 a, 360 b as shown inFIG. 3) into which the portion of each earbud that extends out of itsrespective cavity 110 a, 110 b, extents into. While not shown in FIG. 3,each cavity 360 a, 360 b can be sized and shaped to match the size andshape of the portion of each earbud the cavity surrounds to moresecurely store the earbuds within case 100.

Each earbud can include a speaker assembly (not shown in FIG. 3)disposed within a housing of the earbud. The speaker assembly caninclude a driver unit aligned to emit sound from the directional soundport. The driver unit can include an electromagnetic voice coil, aspeaker diaphragm and a driver magnet (shown in FIG. 3 as magnet 325)operatively coupled to the voice coil to move the diaphragm in responseto electrical signals and produce sound. In addition to the drivermagnet, earbuds according to some embodiments of the disclosure caninclude an additional magnetic plate 330 that is not operatively coupledto the voice coil. Either or both of magnet 325 and magnetic plate 330can be attracted to at least one housing magnetic component 130 disposedwithin case 100. The attraction can be strong enough to magneticallysecure first earbud 115 a into first cavity 110 a and second earbud 115b into second cavity 110 b, as discussed in more detail below. In someembodiments magnetic plate 330 can be made from a magnetic material andin various embodiments it can be made with a metal injection moldingprocess. In some embodiments magnetic plate 330 is magnetized while inother embodiments it is not magnetized but is magnetically attractable.

To increase the magnetic attraction between magnetic component 130 andmagnetic plate 330, the magnetic plate 330 in each earbud can bepositioned direction adjacent to the earbud housing. Additionally, themagnetic plate be contoured to match the curvature of the housingthereby ensuring a minimum distance between the magnetic plate and thehousing across the surface are of the magnetic plate. Similarly, atleast some or the housing magnetic components 130 can be disposed asclose as possible to the surface of the receiving cavity at a locationthat is spaced directly apart from where the magnetic plate 330 will bewhen an earbud is received within the cavity. In some embodiments thehousing components 130 can be contoured to match the curvature of thereceiving area (which matches the curvature of its respective earbud) tominimize the distance between the housing magnetic component 130 and themagnetic plate 330.

In some embodiments housing 105 and lid 120 can be made from the samematerial while in various embodiments they can be made from differentmaterials. In some embodiments both housing 105 and/or lid 120 can bemade from a plastic material, stainless steel, aluminum or any othermaterial.

Charging system 125 can include a circuit board 335 or other electricalrouting structure, a rechargeable case battery 227, electricalinterconnects 340 to pair of earbuds 115 a, 115 b, one or moreelectronic components, such as case processor 210, and an electricalconnector 345 for connecting to power source 205 (see FIG. 2). In someembodiments connector 345 can, for example, be a non-proprietaryinterface such as a USB connector or can be a proprietary interface suchas the Lightning connector developed by Apple Inc. In variousembodiments connector 345 can be liquid-tight, as discussed in moredetail below. One or more charge indicators 235 can be visible on anexterior surface 350 of case 100. In some embodiments each earbud inpair of earbuds 115 a, 115 b can be electrically coupled to chargingsystem 125 by a connector 347 disposed at an end of a stem portion ofeach earbuds 115 a, 115 b, as discussed in more detail below.

Earbud Connectors

FIGS. 4A-8C illustrate several examples of electrical connectors thatcan be used between each individual earbud in pair of earbuds 115 a, 115b and case 100 (see FIG. 3), similar to connector 347 in FIG. 3. Whileeach of FIGS. 4A-8C illustrate an earbud connector for a first earbud115 a, it is to be understood that second earbud 115 b can be configuredidentical to first earbud 115 a and thus include a similar electricalconnector. Additionally, while the embodiments illustrated in FIGS.4A-8C include external contacts that are disposed at the end of a stemof the earbud, the contacts can be at different locations in otherembodiments.

FIGS. 4A and 4B are simplified cross-sectional views of an electricalconnector 400 that can be incorporated into earbud case 100 and anelectrical connector 405 at the end of a stem portion of an earbud 115 aaccording to an embodiment of the disclosure. Electrical connector 405can be used to conduct power and/or data according to some embodimentsof the disclosure. Connector 405 can be part of an earbud interface andcan include first and second earbud contacts 410, 415, respectively. Abottom view of electrical connector 405 is illustrated in FIG. 4B. Insome embodiments, earbud contacts 410, 415 can be annular and separatedby an insulator 420. Receptacle connector 400 can be used in a case suchas case 100 illustrated above and can have a first earbud case contact425 and a second earbud case contact 430. First annular contact 410 caninterface with first earbud contact 425 and second annular contact 415can interface with second earbud contact 430. First and second annularcontacts 410, 415 can be any type of conductive material including gold,silver or palladium plated copper.

In some embodiments first and second earbud contacts 410, 415,respectively are power and ground contacts. That is, either of first andsecond earbud contacts 410, 415, respectively can be used for powerwhile the other can be used for ground. As examples, in some embodimentsfirst contact 410 is used for power and second contact 415 is groundwhile in other embodiments first contact 410 is used for ground andsecond contact 415 is used for power. In various embodiments otherconnector configurations can be used that have more than two contacts.

First and second earbud case contacts 425, 430 can be coupled tocharging system 125 (see FIG. 3) with electrical interconnects 340 incase 100 to facilitate charging and communication of each earbud 115 a,115 b. In various embodiments a circular microphone aperture 435 can belocated in the center of second annular contact 415 of each earbud 115a, 115 b to facilitate two way telephonic communication and/or noisecancellation. Microphone aperture 435 can be covered by an aestheticacoustic mesh to protect the microphone from debris and damage.

FIGS. 5A and 5B illustrate another example receptacle connector 500 thatcan be incorporated into earbud case 100 and an electrical connector 505at the end of a stem portion of an earbud 115 a according to anembodiment of the disclosure. Connector 500 has one annular contact andone center contact, however, as described in more detail below.Connector 505 can be part of an earbud interface and can include firstand second earbud contacts 510, 515, respectively. A bottom view ofelectrical connector 505 is illustrated in FIG. 5B. In some embodiments,ring contact 510 can be ring shaped and circular contact 515 can becircular with the contacts separated by an insulator 520 (e.g.,insulator 520 can be an air gap). Ring contact 510 can interface withfirst earbud contact 525 and circular contact 515 can interface withsecond earbud contact 530. In various embodiments a circular microphoneaperture 535 can be located between ring contact 510 and circularcontact 515 so one or more of pair of earbuds 115 a, 115 b can be usedfor two way telephonic communication.

FIGS. 6A and 6B illustrate another example receptacle connector 600 thatcan be incorporated into earbud case 100 and an electrical earbudconnector 605 disposed at the end of a stem portion of an earbud 115 aaccording to an embodiment of the disclosure. Receptacle connector 600can make electrical contact with electrical earbud connector 605 asdescribed in more detail below. Earbud connector 605 can be part of anearbud interface and can include first and second earbud contacts 610,615, respectively. A bottom view of electrical earbud connector 605 isillustrated in FIG. 6B. As shown in FIG. 6B, contacts 610, 615 can bespaced from each other in an oppositional and symmetrical relationship.In some embodiments, each of earbud contacts 610 and 615 can have apartial annular shape (i.e., a partial ring) with the open portions ofeach contact facing the other. For example, contact 610 can include ends610 a, 610 b and contact 615 can include ends 615 a, 615 b where end 610a is spaced apart from end 615 a and end 610 b is spaced apart from end615 b. While FIG. 6B illustrates each of contacts 610, 615 as halfrings, in other embodiments the contacts can include shorter length arcsand/or have different opposing shapes altogether.

Earbud contacts 610, 615 can be separated from each other by aninsulator 620 (e.g., insulator 620 can be a dielectric material asdiscussed in more detail below). Earbud contact 610 can interface withfirst earbud case contact 625 and earbud contact 615 can interface withsecond earbud case contact 630. In various embodiments a circularmicrophone aperture 635 can be located between earbud contacts 610 and615 enabling pair of earbuds 115 a, 115 b to be used for two waytelephonic communication. Receptacle connector 600 can include a contactcarrier 640 that retains earbud case contacts 625, 630 as described inmore detail below. In some embodiments, contact carrier 640 can makeearbud receptacle cavity 645 liquid-tight.

In some embodiments, each of the first and second earbud contacts 610,615, respectively, can include a contact portion that extends into anearbud receiving cavity of the earbud case when the earbud is positionedwithin the cavity. Receptacle connector 600 can include a pair of earbudcase contacts 625, 630 that are positioned on opposite sides of andextend into the earbud receiving cavity. Earbud case contacts 625, 630can be held within receiving slots 628, 633 of a contact carrier 640 asdiscussed further below. The contact portion of each earbud contact 610,615 can have an arcuate cross-section that makes contact with arcuatecontact portions 626, 631 of contacts 625, 630 respectively, during amating event when the earbud is inserted into the earbud receivingcavity. The combination of arcuate surfaces on the earbud contact andearbud case contact enable a contact wiping motion each time the earbudsare inserted within and drawn out of the receptacle connector, creatinga reliable interconnect. In FIG. 6A, contacts 625, 630 are illustratedin a deflected state that illustrates their approximate position whenearbud 115 a is fully inserted into its receiving cavity such that theearbud contact is engaged with the earbud case connector.

The same contacts 625, 630 are also illustrated in FIG. 6A in anon-deflected state 627, 632 showing the contacts extending into theearbud receiving cavity prior to being mated with the earbud contacts ofearbud 115 a. During a mating event, as earbud 115 a is inserted deeperinto the earbud receiving cavity, the earbud case contacts 625, 630 comein contact with the earbud contacts and deflect outward. The exteriorcontacting surfaces of the earbud contacts and earbud case contacts rubagainst each other during both the mating event and during a de-matingevent when the earbud 115 a is withdrawn from the earbud receivingcavity. In various embodiments the deflecting arcuate portions 626, 631of contacts 625, 630 respectively, are deflected by arcuate portions offirst and second earbud contacts 610, 615, respectively during insertionand withdrawal of the first and second earbuds. Since the arcuateportions are in direct contact and contacts 625, 630 are in a deflected(e.g., spring loaded state), pair of earbuds 115 a, 115 b has a vertical(e.g., ejecting) force applied to them when fully mated with the case.In some embodiments, as discussed in more detail herein, one or moremagnets can be used to overcome the vertical force and hold the earbudswithin their respective cavities.

In some embodiments one of contacts 625, 630 can be arranged to makecontact with the earbud contacts 610, 615, first by preloading one ofcontacts 625, 630 at a different height than the other (e.g., sequentialcontacts). This can be useful in some embodiments to make a groundconnection to the earbud first before making an active electricalconnection with it. The wiping contacts and the sequentially contactingcontacts can be used in any of the connector embodiments disclosedherein.

In various embodiments contact carrier 640 can include a debris recess609 disposed below the contact interface region. Debris recess 609 canhave a cup-like shape defined by sidewalls 609 a and can be useful forproviding a location for debris that falls into either earbud cavity.Debris recess 609 can be disposed between earbud case contact receivingslots 628, 633 and spaced apart from the contact area so the debris doesnot interfere with the earbuds making electrical contact with receptacleconnector 600. Debris recess 609 can further be open to the earbudreceiving cavity so that debris can be periodically cleaned out asneeded. In some embodiments a separate debris recess 609 is disposedunder each earbud contact area while in other embodiments a singledebris recess can be sufficiently wide to capture debris from bothcontact areas.

Debris recess 609, or a similar debris capture structure, can beincluded in any of the connector embodiments disclosed herein. In oneembodiment debris recess 609 has a depth below arcuate portions 626, 631of contacts 625, 630 that is 50 percent or more than a diameter ofdebris recess 609. In another embodiment debris recess 609 has a depththat is 75 percent or more than the diameter of debris recess 609 whilein another embodiment its depth is 100 percent (e.g., having a depth todiameter ratio of 1:1) or more of the diameter.

In some embodiments contacts 625, can be made out of a copper, nickeland silver alloy while in other embodiments they can be made out of aphosphor and bronze alloy, and in other embodiments a different alloycan be used.

Now referring to FIG. 6C an exploded view of receptacle connector 600 isshown. As shown in FIG. 6C, connector 600 includes first and secondshells 650, 655 that define receiving cavities for a pair of earbudsretaining and guiding a stem portion of each earbud into case 100 (seeFIG. 1). While not shown in FIG. 6C, the receiving cavity in each shellcan include an elongated tube portion that opens to a larger earbudreceiving opening. The elongated tube portion can be sized and shaped toaccommodate the stem section of an earbud and the larger earbudreceiving opening can be sized and shaped to partially or fullyaccommodate the ear interface portion (i.e., the portion of the earbudthat fits within a user's ear).

In some embodiments shells 650, 655 can be separate components joinedtogether by the contact carrier while in other embodiments shells 650,655 can be a single component that can be formed, for example, in amolding process, a 3D printing process or with a milling process.Contact carrier 640 holds first and second earbud contacts 625, 630,respectively, that can interface with a first earbud, and also holdsthird and fourth earbud contacts 660, 665, respectively, that caninterface with a second earbud. A collar 670 can be bonded to a topsurface 675 of contact carrier 640. In some embodiments collar 670 canhave a removable tie bar (not shown in FIG. 6C) that holds the threepieces of the collar together during assembly and that can then beremoved after assembly such that the tie bar is not included within afinished earbud case.

Distal ends 680, 685 of first and second shells 650, 655, respectively,can be narrower than the elongated tube portion of shell 650, 655, andeach distal end 680, 685 can be fit within and bonded to collar 670forming a completed shell and receptacle connector assembly 690,illustrated in FIG. 6D. In the completed assembly, each earbud casecontact 625, 630 fits within a respective contact opening of shell 650and each earbud case contact 625, 630 fits within a respective contactopening (e.g., opening 687 visible in FIG. 6C) of shell 655. Eachcontact opening (e.g., opening 687) enables its respective contact toextend into the earbud receiving cavity within its respective shell 650,655 to make electrical contact with an earbud contact during a matingevent. When assembled, shell and contact assembly 690 can create aliquid-tight seal as defined herein. Shell and contact assembly 690 cansubsequently be assembled into a case, such as case 100 illustrated inFIG. 1. In some embodiments first and second shells 650, 655 can be asingle shell having two cavities, one cavity for each earbud.

As defined herein, a liquid-tight seal shall mean a seal that conformsto one or more of the following ratings as defined by the InternationalProtection Rating and International Electrochemical Commission (IEC)60529 that can also be known as the I.P.68 rating. In some embodimentsthe liquid-tight seal will protect the connector assembly against theharmful ingress of water and have a “liquid ingress” rating between 1(dripping water) and 8 (immersion beyond 1 meter). In variousembodiments the liquid-tight seal shall be rated between 1 (drippingwater) and 4 (splashing water) while in some embodiments theliquid-tight seal shall be rated between 2 (dripping water with devicetilted at 15 degrees) and 5 (water jet). In various embodiments theliquid-tight seal shall be rated between 3 (spraying water) and 6(powerful water jets) while in some embodiments the liquid-tight sealshall be rated between 4 (splashing water) and 7 (immersion up to 1meter). In various embodiments the liquid-tight seal shall be ratedbetween 5 (water jets) and 8 (immersion beyond 1 meter) while in someembodiments liquid-tight shall mean the seal will protect the electronicdevice against liquid ingress up to 100 feet for 30 minutes.

Now referring to FIGS. 7A and 7B another example of a receptacleconnector 700 is illustrated that is similar to connector 600illustrated in FIGS. 6A and 6B. Receptacle connector 700 has a differentconfiguration for the contacts and the contact carrier, however, asdescribed in more detail below. This embodiment can use the same earbudconnector shown in FIGS. 6A and 6B, where the earbud contacts aresemicircular and separated by an insulator.

A contact carrier 740 holds first and second earbud contacts 725, 730,respectively, that can interface with a first earbud, and also holdsthird and fourth earbud contacts 760, 765, respectively, that caninterface with a second earbud. A cap 770 can be bonded to a bottomsurface 775 of contact carrier 740 with a layer of adhesive 773. Asillustrated in FIG. 7B, distal ends of first and second shells 750, 755,respectively, can be fit within and bonded to contact carrier 740forming a completed shell and receptacle connector assembly 790. Shelland contact assembly 790 can be liquid-tight, meeting one or more of theranges as defined herein. Shell and contact assembly 790 cansubsequently be assembled into a case, such as case 100 illustrated inFIG. 1.

Similar to contact carrier 640, first and second earbud contacts canhave an arcuate cross-section and can make contact with arcuate portionsof receptacle connector contacts 725, 730. The combination of arcuatesurfaces can enable a wiping motion each time the earbuds are insertedwithin and drawn out of the receptacle connector, creating a reliableinterconnect. Further, in some embodiments one contact can be arrangedto make contact with the earbud first. In one example the contacts canbe preloaded at different heights. This can be useful in someembodiments to ground the earbud first before making an activeelectrical connection with it.

Now referring to FIGS. 8A and 8B another example of a receptacleconnector 800 is illustrated that is similar to connector 400illustrated in FIGS. 4A and 4B. Receptacle connector 800 has a differentconfiguration for the inner and outer contacts, however, as described inmore detail below.

In some embodiments, earbud contacts 810, 815 can be annular andseparated by an electrical insulator 820. First annular contact 810 caninterface with first earbud contact 825 and second annular contact 815can interface with second earbud contact 830. First and second annularcontacts 810, 815 can be formed from any type of conductive materialincluding copper and copper alloys and can be plated with any metal. Invarious embodiments a circular microphone aperture 835 can be located inthe center of second annular contact 815 so one or more of pair ofearbuds 115 a, 115 b (see FIG. 1) can be used for two way telephoniccommunication. Microphone aperture 835 can be covered by an aestheticacoustic mesh to protect the microphone from debris and damage.

Similar to contact carrier 640, first and second earbud contacts canhave an arcuate cross-section and can make contact with arcuate portionsof contacts 825, 830 respectively in receptacle connector 800. Thecombination of arcuate surfaces can enable a wiping motion each time theearbuds are inserted within and drawn out of the receptacle connector,creating a reliable interconnect. Additionally, as shown in FIG. 8A, insome embodiments an exterior surface 821 of the earbud stem can be flushwith an exterior side surface of the earbud contacts. Further, in someembodiments one contact can be arranged to make contact with the earbudfirst. In one example the contacts can be preloaded at differentheights. This can be useful in some embodiments to ground the earbudfirst before making an active electrical connection with it.

Now referring to FIG. 8C an exploded view of receptacle connector 800 isshown illustrating how it can be coupled to first and second shells 850,855 that retain and guide a stem portion of each earbud into case 100(see FIG. 1). Contact carrier 840 holds first and second earbud contacts825, 830, respectively, that can be used with a first earbud, and alsoholds third and fourth earbud contacts that can be used with a secondearbud. Contact carrier 840 can be bonded to distal ends 880, 885 offirst and second shells 850, 855, respectively, forming a completedshell and receptacle connector assembly. Shell and contact assembly cancreate a liquid-tight seal as defined herein. Shell and contact assembly690 can subsequently be assembled into a case, such as case 100illustrated in FIG. 1. In some embodiments first and second shells 850,855 can be a single shell having two cavities, one cavity for eachearbud.

In some embodiments the electrical connector (for example connector 405in FIG. 4A) on pair of earbuds 115 a, 115 b may not be an annular (e.g.,ring shaped) external contact-type connector and can be any other typeof electrical connector, such as, but not limited to a pin and socket, apin and contact pad or a wiping arm and contact pad. In variousembodiments one or more contact pads can be located on a verticalportion of the stem portion of the pair of earbuds and a wiping arm caninterface with them. In another example an interface connector can bedisposed on the ear portion of the earbud housing. A mating connectorcan be disposed within the case and can interface with the connectorwhen the earbud is placed in its respective cavity. In some embodimentssuch a connector can be gold plated to minimize corrosion that can occuras a result of being in contact with a user's ear for extended periodsof time. In yet further examples wireless inductive charging of theearbuds can be used.

Magnetic Retention of Earbuds

FIGS. 9A and 9B illustrate front and rear perspective views,respectively, of one of wireless earbuds 115 a, 115 b. As shown in FIGS.9A and 9B, earbuds 115 a, 115 b include an external housing having anear interface portion 903 and a stem portion 910. Ear interface portion903 can be formed to fit at least partially within a user's ear and canbe non-occluding, as discussed in more detail herein. An aestheticacoustic mesh 915 can fit on ear interface portion 903 and allow soundto travel from an internal speaker to a user's ear. Some embodiments canhave one or more user inputs 955 that can be used to answer a call,pause or mute playback, or perform other functions. The outer housingfor pair of earbuds 115 a, 115 b can be made from a plastic materialincluding, but not limited to, ABS or a polycarbonate.

Now referring to FIG. 10, a top view of housing 105 (see FIG. 1) of case100 for pair of earbuds 115 a, 115 b is illustrated. As shown in FIG.10, housing 105 can include multiple retention magnets 905 a-905 h forthe earbuds and one or more sensors. Earbuds 115 a, 115 b can beinserted in cavities 110 a, 110 b and retained in the cavities by theretention magnets 905 a-905 h. Each cavity 110 a, 110 b can include astem section 116 a, 116 b and a bud section 117 a, 117 b. Earbudretention magnets 905 a-905 d are used to retain first earbud 115 a andretention magnets 905 e-905 h are used to retain second earbud 115 b.However, in other embodiments fewer or additional retention magnets 905a-905 h can be used and the magnets can vary in geometry, size andplacement from those depicted.

Lid sensor 220 can be used to detect whether lid 120 (see FIG. 1) isclosed or open. In the embodiments illustrated in FIG. 10, lid sensor220 is disposed between cavities 110 a, 110 b, but the lid sensor can belocated differently in other embodiments. Lid magnets 910 a, 910 b canbe used for operating the lid (not shown in FIG. 10), as discussed inmore detail below, and in some cases can increase the strength ofretention magnets 905 a-h, as also discussed in more detail below.Cross-sectional view A-A is shown in FIG. 11 and illustrates a side viewof how earbud 115 a can be oriented relative to the magnets discussedabove.

FIG. 11 illustrates a cross-sectional view of earbud 115 a in case 100.As shown in FIG. 11, earbud 115 a is secured within cavity 110 a inhousing 105. In some embodiments earbud 115 a can have a speaker magnet325 and/or a magnetic plate 330 positioned to align with earbudretention magnets 905 f and 905 h. Speaker magnet 325 and/or magneticplate 330 can be attracted to one or more earbud retention magnets 905 fand 905 h and one or both can include a magnetic material.

As defined herein, a magnetic material is any material that is capableof being attracted by or acquiring the properties of a magnet to attractmagnetic materials. This includes ferromagnets (i.e., magnets includingiron) as well as non-ferrous magnets. Some example magnetic materialsare, but are not limited to: neodymium, steel, nickel, cobalt, andalnico, an aluminum-nickel-cobalt alloy, some alloys of rare earthmetals, and some naturally occurring minerals such as lodestone. Incomparison, a magnet is a magnetic material that is magnetized so itattracts a magnetic material.

In one embodiment magnetic plate 330 can include a magnetic material andmagnets 905 f and 905 h can be oriented and positioned to be within adistance to attract the magnetic plate with sufficient force to retainearbud 115 a in housing 105 even if the housing is inverted or shaken.However, the strength of retention magnets 905 f, 905 h can be selectedto allow a user to grasp earbud 115 a with their fingers and remove itfrom housing 105 by applying a force greater than the force of magneticretention. In further embodiments one or more of retention magnets 905f, 905 h can be positioned and oriented to attract speaker magnet 325which can assist with attracting earbud 115 a into housing 105 andretaining it. In other embodiments, an earbud ejection mechanism can beincluded in the case. For example, a mechanical ejector that pushes theearbuds out when the lid is opened (or when an ejection button ispushed).

In some embodiments additional magnets such as those depicted in FIG. 10can be used to augment the attraction and retention forces imparted onmagnetic plate 330 and/or speaker magnet 325. More specifically, lidmagnet 910 b can be used to attract lid 120 (or a magnetic material 1105disposed within the lid) and can also be used as a part of a Halbacharray to augment the magnetic field of earbud retention magnets 905 toattract earbud 115 a from a greater distance and to retain it moresecurely. A Halbach array is a special arrangement of permanent magnetsthat augments the magnetic field on one side of the magnetic array whilecancelling the field to near zero on the other side. Retention magnets905 e, 905 f and 905 g (see FIG. 10) can also be used as a part of theHalbach array.

Now referring to FIG. 12, a cross-sectional view B-B of housing 105 isshown from FIG. 10. As shown in FIG. 12 three earbud retention magnets905 e, 905 f and 905 g are disposed within housing 105 to secure earbud115 a within its cavity. In some embodiments, magnets 905 g and 905 ecan have an angled upper surface to partially conform to the circularshape of ear interface portion 805 of earbud 115 a. Any configuration orarrangement of magnets can be used to attract speaker magnet 325 and/ormagnetic plate 330. In some embodiments a carrier 920 can be formed toretain and position one or more of retention magnets 905 a-905 h.

Also, as described above with respect to FIG. 3, the magnetic plate 330in each earbud can be positioned direction adjacent to the earbudhousing and be contoured to match the curvature of the housing (as shownin FIGS. 11 and 12) to ensure a minimum distance between the magneticplate and the housing across the surface are of the magnetic plate andincrease the magnetic attraction between the housing magnetic componentsand magnetic plate 330 using minimal magnetic material. Similarly, someor all of the housing magnetic components 905 a-905 h can be disposed asclose as possible to an appropriate surface of the earbud case andcontoured in shape to match the surface.

Magnetically Actuated Case

FIGS. 13-21 illustrate case 1300 having a lid with a magneticallyactuated over center position and several example magnet geometries. Asshown in FIG. 13, case 1300 can be similar to case 100 illustrated inFIG. 1 and used to retain a pair of earbuds, however case 1300 can beused for myriad other purposes such as, for example, but not limited to,a container for storing medicine, a container for storing cigars or arecharging container for a miniature portable media player.

Now referring simultaneously to FIGS. 13 and 14, in some embodimentscase 1300 can include a housing 1305 having a receiving opening 1301, abottom face 1302 disposed opposite of the receiving opening. Similar tothe cases discussed above, case 1300 can have a closed position,illustrated in FIG. 13 where a housing 1305 is covered by a lid 1310that is pivotally coupled to the housing. Case 1300 can also have anopen position, illustrated in FIG. 14 where lid 1310 is pivotallydisplaced from housing 1305 by an angle theta. Case 1300 can furtherinclude an upper wall 1303 opposite a lower wall 1304 and a firstsidewall 1306 opposite a second sidewall 1307 where the walls extendbetween receiving opening 1301 and bottom face 1302 defining a cavity1308 that communicates with receiving opening 1301. Receiving opening1301 can be further defined by four wall ends 1309 a, 1309 b, 1309 c and1309 d including ends of upper wall 1303, lower wall 1304, firstsidewall 1306 and second sidewall 1307, respectively.

A first pair of magnetic elements 1315 a, 1315 b can be oriented suchthat they repel one another and are disposed proximate pivotable joint1317 with first magnetic element 1315 a of the first pair disposedwithin housing 1305 and a second magnetic element 1315 b of the firstpair disposed within lid 1310. In some embodiments first pair ofmagnetic elements 1315 a, 1315 b can both be magnets. A second pair ofmagnetic elements 1320 a, 1320 b are oriented such that they attract oneanother and are disposed proximate to a wall end 1309 a oppositepivotable joint 1317 with a first magnetic element 1320 a of the secondpair of magnetic elements disposed within housing 1305 and a secondmagnetic element 1320 b of the second pair of magnetic elements disposedwithin lid 1310. In some embodiments both magnetic elements 1320 a, 1320b can be magnets while in another embodiment one of the magneticelements can be a magnet while the other element is a magnetic material.

In some embodiments case 1300 can be configured to create an over centerconfiguration for lid 1310 where the lid is in a first stable positionwhen in the closed position (illustrated in FIG. 13) and is in a secondstable position when in the open position (illustrated in FIG. 14), butis in an unstable position in-between the closed position and the openposition. In some embodiments this can be achieved by the attractiveforces between second pair of magnetic elements 1320 a, 1320 b overpowering the repulsive forces of first pair of magnetic elements 1315 a,1315 b when lid 1310 is transitioned from the open position to theclosed position. This condition can be explained graphically asillustrated in FIG. 15.

In some embodiments any of the magnetic arrangements disclosed hereincan be arranged in a multipole configuration to concentrate the magneticfield within and between the magnets. In some embodiments a multipolecan be used for magnetic elements 1320 a and 1320 b where 1320 a has anorth end adjacent a south end and 1320 b has a south end that attractsto 1320 a's north end, and has a north end that attracts to 1320 a'ssouth end. In other embodiments any other arrangement can be used. Amultipole arrangement can be beneficial to attenuate magnetic fieldsoutside of the case so they don't negatively interact with othermagnetic objects such as cards with magnetic strips on them.

FIG. 15 illustrates a graph of the magnetic forces on lid 1310. As shownin FIG. 13, lid 1310 has an over center position due to forces impartedon it from two pairs of magnetic elements. As discussed above, firstpair of magnetic elements 1315 a, 1315 b (see FIGS. 13 and 14) areoriented to have repulsive forces which are shown as the line on thegraph labeled F_(Repulsion). Similarly, second pair of magnetic elements1320 a, 1320 b are oriented to have attractive forces which are shown asthe line on the graph labeled F_(Attraction). From examination of FIG.14 it can be seen than an angle of theta=0° is when lid 1310 is closedand an angle of theta=180° is when the lid is fully open (e.g.,pivotally displaced from housing 1305 to its maximum extent). At someangle labeled X° is an over center position for lid 1310 where it isunstable and it will “automatically” (i.e., through magnetic attraction)move either towards the closed position or the open position.

Continuing to refer to FIG. 15, at an angle of 0° lid 1310 is closed andthe attractive forces (F_(Attraction)) of second pair of magneticelements 1320 a, 1320 b are greater than the repulsive forces(F_(Repulsion)) of first pair of magnetic elements 1315 a, 1315 b so thelid is secured in the closed position. In some embodiments, even iffirst pair of magnetic elements 1315 a, 1315 b and second pair ofmagnetic elements 1320 a, 1320 b have the same strength, the over centerdesign will work since the leverage the first pair of magnetic elementshas on the pivotable joint is less than the leverage the second pair ofmagnetic elements has on the pivotable joint. More specifically, sincefirst pair of magnetic elements 1315 a, 1315 b are closer to thepivotable joint it will apply less torque to lid 1310 than second pairof magnetic elements 1320 a, 1320 b.

However, as lid 1310 transitions to greater angles of theta (i.e., whentransitioning to an open position), second pair of magnetic elements1320 a, 1320 b moves apart from one another faster than first pair ofmagnetic elements 1315 a, 1315 b. Since magnetic forces varyexponentially with distance, the F_(Attraction) falls much faster thanF_(Repulsion), therefore at some angle of X° the F_(Repulsion) overcomesthe F_(Attraction) and the lid will be attracted to the open position.When transitioning from the open position to the closed position thereverse happens and after the over center point is reached the lid willbe attracted to the closed position.

In some embodiments first pair of magnetic elements 1315 a, 1315 b canbe configured to stop lid 1310 from fully opening (i.e., where theta is180°). In some embodiments first pair of magnets 1315 a, 1315 b can beconfigured to be repulsive, therefore in such embodiments the magneticelements could be elongated such that when lid 1310 rotates close to the180° open position first pair of magnetic elements 1315 a, 1315 b repeleach other such that the weight of the lid is supported by theirrepulsive force and the lid is essentially suspended in a semi-openposition. Some shapes of magnets such as an “L” can be used to enhancethe forces to support lid 1310 in a semi-open position. In variousembodiments the force vector of first pair of magnetic elements 1315 a,1315 b can be adjusted to increase or decrease this effect, as discussedin more detail below.

In some embodiments case 1300 can be designed to have a particular feelfor a user. For example, in one embodiment case 1300 can be designed soa user can hold case 1300 in their hand in the closed position and bysnapping their wrist lid 1310 will snap open and remain in the openposition without resting against 1305. In further embodiments lid 1310can be in the open position and the user can snap their wrist and closethe lid. In further embodiments a user can use their hand to try to openlid 1310 and once the lid has been moved a certain distance the lid willsnap or spring open. In further embodiments a user can grasp lid 1310and move it towards the closed position and at a certain distance thelid will snap or spring closed.

Now referring to FIG. 16 another embodiment of a case 1600 with amagnetically actuated lid 1604 is illustrated. As shown in FIG. 16, case1600 has one pair of magnetic elements having misaligned poles (i.e.,force vectors) and another pair of magnetic elements having a highpermeability material used to increase magnetic forces. Similar toprevious embodiments, lid 1604 is pivotally attached to housing 1603.However, in this case first pair of magnetic elements 1605 a, 1605 b areoriented so the force vectors are not directly aligned as illustrated bythe arrows. In this scenario, lid 1604 can still have an over centerposition, however the F_(Repulsion) from first pair of magnetic elements1605 a, 1605 b will be less than the scenario illustrated in FIG. 13.However, one feature of such a misalignment of force vectors can be usedto resist lid 1604 from transitioning to a 180° fully open position.More specifically, magnetic forces from first pair of magnetic elements1605 a, 1605 b can resist lid 1604 from going to the closed position,but can also resist lid from going to the 180° open position. Othervariations of misaligned magnetic force vectors can be used and arewithin the scope of this disclosure.

Continuing to refer to FIG. 16, second pair of magnetic elements 1610 a,1610 b can have a high permeability material 1615 a, 1615 b at leastpartially surrounding them to increase the forces of attraction betweenthe second pair of magnetic elements. A high permeability material asdiscussed herein can be any material with a relatively highpermeability. The permeability of a material is the measure of thematerial's ability to support the formation of a magnetic field withinitself. More specifically, it is the degree of magnetization that amaterial obtains in response to an applied magnetic field. Thus, themore “magnetically conductive”, or the less resistant a material is tomagnetic fields, the higher its permeability. Following this behavior,high permeability material 1615 a, 1615 b as discussed herein canessentially re-direct the magnetic fields from second pair of magneticelements 1610 a, 1610 b so the attractive forces are increased. Highpermeability materials can also be used on repulsive magnets, lidmagnets or magnets used to attract and secure earbuds within the case.

FIG. 17 illustrates another embodiment of a case 1700. As shown in FIG.17, case 1700 has springs attached to the first and second pairs ofmagnetic elements to change the over center behavior of the lid. Case1700 can have a first pair of magnetic elements 1705 a, 1705 bconfigured to be repulsive and a second pair of magnetic elements 1710a, 1710 b configured to attract. However, in this embodiment springs1707 a, 1707 b can be attached to first pair of magnetic elements 1705a, 1705 b and springs 1717 a, 1717 b can be attached to second pair ofmagnetic elements 1710 a, 1710 b. Springs 1707 a, 1707 b, 1717 a, 1717 bcan be used to change the over center position and behavior of lid 1704.For example, when in the closed position, first and second magneticelements 1705 a, 1705 b can repel each other and compress springs 1707a, 1707 b, relieving some of the repulsive forces. Conversely, while inthe closed position second pair of magnetic elements 1710 a, 1710 b canbe attracted closer together resulting in higher attractive forces sincesprings 1717 a, 1717 b allow the magnetic elements to move closertogether. Other configurations of springs can be used with magneticelements without departing from this disclosure.

Now referring to FIGS. 18-21, various magnet geometries can be used inthe cases discussed above. These are only examples, and other geometriescan be used without departing from the disclosure. FIG. 18 shows asquare bar 1800, while FIG. 19 shows a rectangular bar 1900. FIG. 20shows an “L” shaped bar 2000 while FIG. 21 shows a cylindrical bar 2100.

Spring Actuated Case

Now referring to FIGS. 22A-22D a case and a spring actuated hinges areillustrated. As shown in FIG. 22A, case 2200 has a lid 2210 with aspring actuated over center mechanism 2220. Case 2200 can be similar tocase 100 illustrated in FIG. 1 and case 1300 illustrated in FIG. 13 andin some embodiments can used to store and charge a pair of earbuds orother type of portable listening device. In other embodiments, howevercase 2200 can be used to store a variety of other objects different thanportable listening devices.

Similar to the cases discussed above, case 2200 can have a closedposition, illustrated in FIG. 22A where a housing 2205 is covered by alid 2210 that is pivotally coupled to the housing. Case 2200 can alsohave an open position, illustrated in FIG. 22D where lid 2210 ispivotally displaced from housing 2205. A spring actuated over centermechanism 2220 is shown in more detail in the expanded view in FIG. 22A.Lid 2210 includes an extension 2225 attached to the lid and disposed onan opposite side of pivotable joint 2230 from the lid. That is, when lid2210 rotates about pivotable joint 2230, extension 2225 also rotatesabout the pivotable joint. Extension 2225 has a rounded distal end 2226that is in contact with a spring loaded arm 2235 such that the lidresists rotating from the open position to the closed position until thelid is moved past an over center position (illustrated in FIG. 22C) whenthe lid is then impelled to the closed position (illustrated in FIG.22D).

Spring loaded arm 2235 is attached to a second pivotable joint 2240 at afirst end and extends to a distal tip 2245. Spring loaded arm 2235 canhave a rounded distal tip 2245 with a first and second surface 2246,2247, respectively arranged opposite each other and extending betweenthe distal tip and the first end. In the illustration in FIG. 22A,spring loaded arm 2235 has a rotational force from a torsion springapplying a clock-wise torque. As lid 2210 is moved towards the openposition, extension 2225 rotates in a clock-wise direction aboutpivotable joint 2230, slides along a first portion 2248 of first surface2246, and forces arm 2235 in a counter-clock-wise direction increasingthe clock-wise torque on the arm. Thus, spring loaded mechanism 2220resists lid 2210 transitioning from the closed position (illustrated inFIG. 22A) towards the open position (illustrated in FIG. 22D.)

FIG. 22B illustrates an isometric view of spring loaded mechanism 2220.As shown in FIG. 22B, spring loaded mechanism 2220 includes a springloaded arm 2235, extension 2225, torsion spring 2250 and spring stop2255. Torsion spring 2250 is formed around a pin of second pivotablejoint 2240, however in other embodiments a different configuration forthe mechanism can be used including, but not limited to, cantileveredsprings and coil springs.

FIG. 22C illustrates case 2200 with a partially open lid 2210. As shownin FIG. 22C, lid 2210 is shown in an over center position where the lidis in a first stable position when in the closed position (illustratedin FIG. 22A) and is in a second stable position when in the openposition (illustrated in FIG. 22D), but is in an unstable positionin-between the closed position and the open position. In someembodiments the over-center performance of lid 2210 can be achieved byextension 2225 having a rounded distal end 2226 that is in contact witharm 2235 that has a clockwise torque applied to it. In variousembodiments extension 2225 is oriented perpendicular to first surface2246 when in the unstable position in-between the closed position andthe open position. In some embodiments arm 2235 and or distal end 2226can have a lubricant and/or one or more lubricant channels on it tomaintain a low coefficient of friction between the parts and to providesmooth actuation.

FIG. 22D illustrates case 2200 with a fully open lid 2210. As shown inFIG. 22D, lid 2210 is past the over-center position and is in a stableopen position. In some embodiments the stable position can be achievedby extension 2225 being past the over center location on arm 2235, withextension 2225 sliding along a second portion 2249 of first surface2246, and the arm holding the lid open due to the clock-wise torqueapplied to the arm by torsion spring 2250 (see FIG. 22B).

Earbud Case with Wireless Charging Transmitter

Reference is now made to FIG. 23, which illustrates an earbud case 2300that includes a wireless power transmitting component 2330 that enablesthe case to wirelessly charge an accessory electronic device outside ofthe case instead of within the case. For example, as shown in FIG. 23,case 2300 is depicted as wireless charging a watch 2301 that is placedover and aligned with wireless power transmitting component 2330. WhileFIG. 23 illustrates a watch as the accessory device being charged,embodiments of the disclosure can be used to wirelessly charge otherappropriate electronic devices as well. In some instances, embodimentsof the disclosure are particularly well suited for use with portableelectronic media devices because of their potentially small form factor.As used herein, an electronic media device includes any device with atleast one electronic component that can be used to presenthuman-perceivable media. Such devices can include, for example, portablemusic players (e.g., MP3 devices and Apple's iPod™ devices), portablevideo players (e.g., portable DVD players), cellular telephones (e.g.,smart telephones such as Apple's iPhone devices), video cameras, digitalstill cameras, projection systems (e.g., holographic projectionsystems), gaming systems, PDAs, as well as tablet (e.g., Apple's iPaddevices), laptop or other mobile computers. Some of these devices can beconfigured to provide audio, video or other data or sensory output.

In the embodiment illustrated in FIG. 23, case 2300 can include all orsome of the features of case 204 discussed above with respect to FIG. 2along with a second charging system in which a wireless powertransmitting component 2330 is positioned within housing 2335 adjacentto an exterior charging surface 2340. In some embodiments exteriorcharging surface 2340 can be any exterior surface of case 2300. Wirelesspower transmitting component 2330 can be configured to wirelesslytransmit power across housing 2335 to a power receiving coil (not shownin FIG. 23) of watch 2301 when the watch is positioned outside housing2335 adjacent to exterior charging surface 2340, as discussed in moredetail below.

As further shown in FIG. 23, watch 2301 includes a casing 2302 thathouses a display 2304 and various input devices including a dial 2306and a button 2308. Watch 2301 can be worn on a user's wrist and securedthereto by a band 2310. Casing 2302 also houses electronic circuitry(not shown in FIG. 23), including a processor and communicationcircuitry. A battery (not shown in FIG. 23) internal to casing 2302powers watch 2301. The battery can be recharged by a wireless powertransfer system and watch 2301 can include circuitry configured tooperate as a receiver in the wireless power transfer system whilewireless power transmitter component 2330 is a transmitter in thesystem. One example of a wireless power transfer system is an inductivepower transfer system. In an inductive power transfer system, apower-receiving electronic device includes or otherwise incorporates aninductive power-receiving element configured to wirelessly receive powerand/or charge one or more internal batteries. Similarly, a chargingdevice (i.e., power transmitting component) includes or otherwiseincorporates an inductive power-transmitting element configured towirelessly transmit power to the power-receiving electronic device.

FIG. 24 is a block diagram of inductive power receiving system 2400according to an embodiment of the present disclosure. As shown in FIG.24, system 2400 is an inductive power receiving system that can belocated within casing 2302 of watch 2301 (see FIG. 23) or within adifferent type of electronic accessory that can be charged by wirelesspower transmitting component 2330. When power receiving system 2400 isoperatively coupled with an appropriate inductive power transmittingcomponent, such as wireless power transmitting component 2330, battery2402 within the device can be wirelessly charged. Battery 2402 isoperably connected to a receive coil 2404 via power conditioningcircuitry 2406. Receive coil 2404 can be inductively coupled to atransmit coil of a charging device to receive power wirelessly from thecharging device and pass the received power to battery 2402 within theelectronic device via power conditioning circuitry 2406. Powerconditioning circuitry 2406 can be configured to convert the alternatingcurrent received by the receive coil 2404 into direct current power foruse by other components of the device. A processing unit 2410 can directthe power, via one or more routing circuits and under the execution ofan appropriate program residing in a memory 2412, to perform orcoordinate one or more functions of the electronic device typicallypowered by battery 2402.

Now referring to FIG. 25, case 2300 is illustrated with a pair ofearbuds 115 a, 115 b stored within a housing 2505 of the case andcovered by a lid 2520. Case 2300 can charge earbuds 115 a, 115 b in thesame manner as case 100 discussed above (i.e., either with a wiredconnection or with a wireless power transfer system). Case 2300 canalso, however, include an inductive charging system 2525 positioned andconfigured to charge a different portable electronic device positionedoutside of case 2300 instead of within the case. Inductive chargingsystem 2525 can include a wireless power transmitting component towirelessly charge an auxiliary device such as watch 2301 (see FIG. 23).In some embodiments case 2500 can be different from case 100 (seeFIG. 1) and can be of any other configuration having one or morecavities and a lid that covers the one or more cavities. In one examplelid 2520 can be separable from the case. Inductive charging system 2525can include wireless charging circuitry within housing 2505 that enablescase 2300 to wirelessly recharge a battery, for example, battery 2402(see FIG. 24) of watch 2301.

FIG. 26 is a block diagram of a wireless charging system 2600 accordingto an embodiment of the disclosure. As shown in FIG. 26, wirelesscharging system 2600 includes an inductive power transmitting component2602. Inductive power transmitting component 2602 includes a powersource 2604, which can be case battery 227 (see FIG. 2), operativelycoupled to a transmit coil 2606 to transmit power to a wearable devicevia electromagnetic induction or magnetic resonance.

Transmit coil 2606 can be an electromagnetic coil that produces atime-varying electromagnetic flux to induce a current within anelectromagnetic coil within an electronic device (e.g., coil 2404 inFIG. 24). Transmit coil 2606 can transmit power at a selected frequencyor band of frequencies. In one example the transmit frequency issubstantially fixed, although this is not required. In another example,the transmit frequency can be adjusted to improve power transferefficiency for particular operational conditions. More particularly, ahigh transmit frequency can be selected if more power is required by theaccessory and a low transmit frequency can be selected if less power isrequired by the accessory. In other examples, transmit coil 2606 canproduce a static electromagnetic field and can physically move, shift,or otherwise change its position to produce a spatially-varyingelectromagnetic flux to induce a current within the receive coil.

When watch 2301 (see FIG. 23) is operatively coupled (e.g., disposed onor adjacent to) case 2300, the wearable electronic device can receivecharge to replenish the charge of its rechargeable battery or to providepower to operating components associated with the electronic device. Tofacilitate the transfer of electromagnetic energy, transmit coil 2606can be positioned within the housing of case 2300 (see FIG. 23) suchthat it aligns with receive coil 2404 (see FIG. 24) in watch 2301 alonga mutual axis. If misaligned, the power transfer efficiency betweentransmit coil 2606 and receive coil 2404 (see FIG. 24) can decrease asmisalignment increases. In some embodiments, one or more alignmentfeatures can be used to aid the alignment along a mutual axis, includingmechanical alignment features (e.g., recesses, ledges, detents) andmagnetic features (e.g., alignment magnet 2630), as discussed in moredetail below.

As one example, alignment magnet 2630 can be included in case 2300 thatmagnetically mates with an alignment magnet (not shown) of watch 2301 tofacilitate proper alignment of the case and the wearable electronicdevice. More specifically, alignment magnet 2630 attracts the matingalignment magnet in watch 2301 such that the wearable device islaterally moved into a particular location and held firmly against anouter surface of the case. Additionally, the top and bottom surfaces ofcase 2300 and watch 2301, respectively, can cooperate to furtherfacilitate alignment. For example, in one embodiment a bottom surface ofwatch 2301 is convex and a top surface of case 2300 is concave,following the same curvature as the bottom surface of the wearabledevice.

In some embodiments, case 2300 (see FIG. 23) can also include one ormore sensors to determine whether watch 2301 is present and ready toreceive transmitted power from the charger. For example, watch 2301 caninclude an optical sensor, such as an infrared proximity sensor. Whenwatch 2301 is attached to case 2300, the infrared proximity sensor canproduce a signal used to determine the presence of the wearable device.Other methods or structures to verify the presence of watch 2301 caninclude a mass sensor, a mechanical interlock, switch, button or thelike, a Hall-effect sensor, or other electronic sensor.

Some embodiments can include a prioritized charging algorithm topreferentially use the stored charge in case battery 227 (see FIG. 2)depending on what chargeable devices are coupled to case 2300. Forexample charging system 2525 (see FIG. 25) can be programmed to firstrecharge earbuds 115 a, 115 b, then charge watch 2301. In anotherexample a user is able to program the charging priority while in anotherexample case 2300 can simply charge any device that is coupled to it. Infurther examples case 2300 can be coupled to a power source throughconnector 345 (see FIG. 3) and can charge one device, preferentiallycharge multiple devices or simultaneously charge multiple devices.

Some embodiments can have a wired interface for case 2300 chargingbattery 2402 (see FIG. 24) and/or for exchanging data with watch 2301.The wired interface can be in addition to or instead of a wirelessinterface. For example, in one embodiment case 2300 can include contactsthat are sized and positioned to physically and electrically couple toone or more contacts on watch 2301. The contacts can include one or morepower contacts as well as one or more data contacts, such as a pair ofdifferential data contacts. In another embodiment connector 345 (seeFIG. 3) of case can be used to charge watch 2301.

Wirelessly Charged Case

Now referring to FIG. 27, a simplified perspective view of case 2700 ona charging station 2705 is illustrated. As shown in FIG. 27, case 2700can be similar to other cases in this disclosure, such as case 100 inFIG. 1, and can be inductively charged by a charging station 2705. Case2700 can have a rechargeable battery that can be inductively rechargedwith a wireless charging system similar to that illustrated anddescribed above with reference to FIGS. 23 through 26. Morespecifically, all of the features described above with regard toinductively charged watch 2301 can be employed in inductively chargedcase 2700.

Wireless charging station 2705 can include wireless charging circuitrywithin housing 2710 that enables case 2700 to wirelessly recharge aninternal battery. Wireless charging station 2705 can include aninductive power transmitting coil 2715, that is similar to wirelesspower transmitting component 2602 described above in FIG. 26. Inductivepower transmitting coil 2715 is capable of transmitting power to case2700 via electromagnetic induction or magnetic resonance. When case 2700is operatively coupled (e.g., disposed on or adjacent to) chargingstation 2705, the case can receive charge to replenish the charge of itsrechargeable battery or to provide power to operating componentsassociated with the case.

To facilitate the transfer of electromagnetic energy, transmit coil 2715can be positioned within the housing of charging station 2705 such thatit aligns with one or more receive coils 2720 in case 2700 along amutual axis. If misaligned, the power transfer efficiency betweentransmit coil 2715 and receive coil 2720 can decrease as misalignmentincreases. In some embodiments, one or more alignment features can beused to aid the alignment along a mutual axis, including mechanicalalignment features (e.g., recesses, ledges, detents) and magneticfeatures (e.g., alignment magnet), as discussed herein. In furtherembodiments case 2700 can include more than one receive coil and candetect which receive coil is better aligned and selectively only receivecharge from that particular coil. In various embodiments case 2700 canuse one or more planar receive coils 2720, however in other embodimentsother receive coil designs can be used.

Waterproof Receptacle Connector

FIGS. 28 and 29 illustrate a liquid-tight electrical connector 2800. Asshown in FIG. 28, electrical connector 2800 can have mounting flangesand sealed features to make it resistant or impervious to liquidpenetration. Electrical connector 2800 can be used to couple power anddata to a case, similar to connector 345 in FIG. 3. In some embodimentsconnector 2800 can, for example, be any non-proprietary interface suchas a USB connector or can be any proprietary interface such as theLightning connector used by Apple Incorporated of Cupertino, Calif. Invarious embodiments connector 2800 can be liquid-tight, as discussed inmore detail below.

Metallic bracket 2805 is formed around an exterior portion of connector2800 and has one or more mounting holes 2810 for securing the connectorto a circuit board or a chassis. Connector 2800 has a receiving face2815 that has a front opening (not shown in FIG. 28, but shown in FIG. 3for connector 345) for receiving a plug portion of a mating connector.An interconnection face 2820 contains a plurality of metallic pins 2825that each connect to an internal electrical contact as described in moredetail below. One or more ground pins 2826 can also extend out ofinterconnection face 2820. Metallic pins 2825 and ground pins 2826 canbe sealed by an overmolded portion 2830 so they are liquid-tight.Metallic bracket 2805 can be two pieces and welded together as describedbelow. Metallic bracket 2805 can also have one or more deformablefingers 2835 that can be used to secure the components of connector 2800together.

As shown in FIG. 29 connector 2800 includes a contact plate 2980 coupledto a housing 2905 with a gasket to make the connector liquid-tight.Housing 2905 is made from an electrically insulative polymer thatextends between receiving face 2815 and a rear face 2910. Housing 2905defines a cavity 2915 that communicates with a front opening inreceiving face 2815 to receive a plug portion of a mating plugconnector. A spacer 2920 is formed from a plastic material and has aplurality of retention features 2925 that are each configured to eachreceive an electrical contact from a set of electrical contacts 2930that can be stitched into it. Each electrical contact in the set ofelectrical contacts 2930, can include an elongated beam portion 2935positioned between a contact tip 2940 and an anchor portion 2945. Eachcontact tip 2940 is positioned within cavity 2915 so that it can beelectrically coupled to a corresponding plug connector contact during amating event.

Beam portion 2935 allows tip 2940 of each contact to flex slightlydownward during a mating event and biases the tip to keep physical andelectrical contact with a contact in the plug connector that aligns withthe particular receptacle contact. Anchor portion 2945 can be asubstantially flat plate with one or more cutouts that fits within aslot 2950 of housing 2905 to secure or anchor the contacts in place. Setof electrical contacts 2930 can further include electrical leads 2955that extend out of interconnection face 2820 (see FIG. 28) of connectorassembly 2800 that can couple the receptacle connector to a printedcircuit board or similar substrate. Each contact in the set of contacts2930 can also have an alignment portion 2960 adjacent anchor portion2945 to align the contact structures within slots 2950 of housing 2905.In some particular embodiments, set of electrical contacts 2930 includeseight contacts spaced apart from each other along a single row.

A ground latch 2965 can be formed from a conductive metal and insertedthrough ground slots 2970 in spacer 2920. The ground latch can includefirst and second spring arms extending along opposing sides of the setof contacts 2930. The first and second spring arms can latch toretention features of a corresponding plug connector to assist inretaining the plug connector within the receptacle connector 2800 aftera mating event. In other embodiments ground latch 2965 can be insertmold within spacer 2920. Spacer 2920, with set of contacts 2930 andground latch 2965, can then be overmolded with dielectric overmoldportion 2975. Overmold portion 2975 covers a portion of spacer 2920 andthe anchor portion of each contact in the set of contacts 2930 forming aliquid-tight seal to leads 2955 and ground latch 2965 and creating anintegrated contact plate 2980. A gasket 2985 can be disposed againstrear face 2910 of housing 2905 and contact plate 2980 can then bepressed against the gasket to form a liquid-tight assembly. Metallicbracket 2805 can include a top bracket 2990 a laser welded to a bottombracket 2990 b. Bracket fingers 2835 can be formed to hold contact plate2980 against housing 2905 such that connector 2800 is liquid-tight. Thatis, if liquid were to enter receiving opening of connector (seeconnector 345 in FIG. 3) the liquid would not be able to pass throughthe connector and enter case 100.

Wireless Earbuds

Now referring to FIGS. 30-46, non-occluding earbuds 3000 a, 3000 b andmethods for making the same are described and illustrated. As shown inFIGS. 30 and 31 earbuds 3000 a, 3000 b can be similar to earbuds 115 a,115 b illustrated in FIG. 1, however earbuds 3000 a, 3000 b can includevarious other features including in ear sensing and acoustic features asdescribed in more detail below.

FIGS. 30 and 31 show front and rear perspective views, respectively, ofa non-occluding left earbud 3000 a (FIG. 30) and a non-occluding rightearbud 3000 b (FIG. 31). Generally, non-occluding earbuds are designednot to form an airtight seal between the ear (or ear canal) and theouter surface of the earbud. By way of contrast, occluding earbuds aregenerally designed to fit inside of the user's ear canal and form asubstantially airtight seal. Each earbud 3000 a, 3000 b can include anexternal housing 3005 having an ear portion 3010 coupled to a stemportion 3015. Housing 3005 can have an asymmetric shape amenable toin-the-ear retention, but does not form an airtight seal with the user'sear or ear canal. The absence of an airtight seal can benefit fromvolumes within the earbud being specifically tuned (e.g., byspecifically shaping the volumes and/or adding material to the volumes)to achieve a desired frequency response. Ear portion 3010 can include adirectional sound port 3020 offset with respect to a center axis of theear bud. Directional sound port 3020 can be designed to direct soundwaves from an internal driver (e.g., part of an earbud speaker, notshown in FIGS. 30 and 31) directly into a user's ear canal.

In addition, secondary apertures in the earbud can be employed inhousing 3005 to achieve desired sound performance. For example, one ormore secondary apertures can serve as a controlled leak port to exposean acoustic pressure within the earbud to the external, surroundingenvironment. In this aspect, the secondary apertures can be calibratedto modify an acoustic response of the earbud. In this embodiment earbuds3000 a, 3000 b each include a front leak port 3025 and a multiport 3030formed in ear portion 3010. Multiport 3030 can include both a rear vent3035 and a bass port 3040, that will be described in more detail below.In addition, earbuds according to embodiments of this disclosure can beconstructed to have a seamless finish even though two or more parts arejoined together to form part of the earbud.

Ear portion 3010 of earbuds 3000 a, 3000 b can also include one or more“in the ear” sensors to assist each earbud 3000 a, 3000 b in determiningwhether or not the earbud is in a user's ear. In one embodiment anoptical tragus sensor 3045 is configured to sense the presence orabsence of a user's tragus, and an optical concha sensor 3050 isconfigured to sense the presence or absence of a user's concha. Tragusand concha sensors 3045, 3050, respectively, can use any type of opticalsensor including, but not limited to an LED or vertical cavity surfaceemitting laser (VCSEL) device. Further embodiments can include one ormore capacitive sensors and/or accelerometers to detect the presence ofa user's ear and/or earbud orientation, as described in more detailbelow. In the ear detection can be useful for features such as, but notlimited to, determining which earbud 3000 a, 3000 b to use as amicrophone when a user desires to accept a call and when a user stopsusing one earbud and starts using the other earbud.

A distal end 3055 of stem portion 3015 of each earbud 3000 a, 3000 b caninclude an electrical connector 3060 that is formed to make contact witha corresponding connector (e.g., a receptacle connector) of a chargingstation and/or earbud charging case, such as one of the connectorstructures described in FIGS. 4A-8C. In one particular embodiment, eachconnector 3060 can include first and second contacts spaced apart fromeach other in an oppositional and symmetrical relationship, such aspartially annular earbud contacts 610 and 615 shown in FIG. 6B. Each ofthe first and second contacts can include an outer perimeter that isflush with an exterior surface of the stem portion and include anarcuate or other curved surface that creates a strong wiping actionduring a contact mating event. Electrical connector 3060 can be used torecharge an internal battery within each earbud 3000 a, 3000 b and insome cases can also be used to transfer data to and from each earbud.Distal end 3055 can also include a bottom microphone port 3065 (e.g.,microphone aperture 635 illustrated in FIG. 6B) that works inconjunction with a top microphone port 3070 to receive a user's voiceand/or perform noise cancellation.

FIGS. 32 and 33 illustrate partial cross sections of earbuds 3000 a,3000 b. As shown in FIG. 32, earbuds 3000 a, 3000 b include a driver3205, an acoustic insert 3220, a flexible circuit 3225, an antenna 3330,a rechargeable battery 3335 and an electrical connector 3060. Driver3205 is located within ear portion 3010 and defines a front acousticvolume 3210 in front of the driver and a rear acoustic volume 3215behind the driver. Driver 3205 can include an electromagnetic voicecoil, a driver magnet and a speaker diaphragm (not shown in FIG. 32).Acoustic insert 3220 is positioned behind driver 3205 and adhered tohousing 3005, as described in more detail below. Ear portion 3010further includes a folded up portion of a flexible circuit 3225 that cancontain one or more sensors, controllers and myriad other circuits foroperating earbud 3000 a,b. Flexible circuit 3225 can include portionsthat are flexible as well as portions that are not flexible, such asmultilayer epoxy and glass composite circuit boards and can furthercouple the myriad electronic systems of earbud 3000 a, 3000 b together,as described in more detail below.

Stem portion 3015 of earbud 3000 a, 3000 b can include an antenna 3330,a rechargeable battery 3335 and electrical connector 3060. A portion offlexible circuit 3225 can extend down and electrically connect toelectrical connector 3060.

As shown in FIG. 33, earbuds 3000 a, 3000 b include several internalsensors. In FIG. 33 some internal components of earbud 3000 a, 3000 bhave been removed for clarity. Ear portion 3010 can contain a tragussensor 3045, a concha optical sensor 3050 and an accelerometer 3315 thatcan work together to determine whether earbud 3000 a, 3000 b is in auser's ear. Flexible circuit 3225 (see FIG. 32) can be used toelectrically couple all these devices together.

Foldable, Flexible Circuit

FIGS. 34 and 35 illustrate simplified views of flexible circuit 3225. Asshown in FIG. 34, flexible circuit 3225 is shown in a flat pattern. FIG.35 shows flexible circuit 3225 folded up as it is installed in earbud3000 a, 3000 b as shown in FIG. 32. Now referring simultaneously toFIGS. 34 and 35 the various portions of flexible circuit 3225 aredescribed. A concha portion 3405 can be used to attach to andcommunicate with optical concha sensor 3050 (see FIG. 33). Towards thispurpose, concha portion 3405 can include one or more electricalterminals that can be bonded to contacts of optical concha sensor 3050.

Processor portion 3410 can include one or more central processing units,controllers and passives. Processor portion 3410 can be a rigid portionof flexible circuit 3225 and can include multiple stacked routinglayers. In one embodiment processor portion can have 4, 6, 8 or 10routing layers.

An accelerometer portion 3415 can include one or more accelerometers toassist in detecting a position and/or orientation of the earbud, toassist in acting as a microphone that may be used to mitigate wind noiseand to function as a user input device recognizing a tap or touchingsequence on the earbud housing. A top microphone portion 3420 can beused to attach to and communicate with a top microphone through one ormore electrical terminals. A tragus sensor portion 3430 can be used toattach to and communicate with optical tragus sensor 3045 (see FIG. 33)through one or more 3430 formed within portion, and a bottom microphoneportion 3435 can be used to attach to and communicate with a bottommicrophone through one or more terminals formed within portion 3435.

Each of the flexible portions 3440 can be sufficiently flexible to foldup flexible circuit 3225 as illustrated in FIG. 35. Further, each of theflexible portions 3440 can include one or more electrical traces thatroute electrical signals between different components of flexiblecircuit 3225. For example, flexible portion 3440 between concha portion3405 and processor portion 3410 can include one or more electricaltraces that run between the concha portion terminals and the processor.Similarly, flexible portion 3440 between bottom microphone portion 3435can include one or more electrical traces that run between the bottommicrophone terminals and the processor.

Earbud Connectors

FIGS. 36-41 illustrate several embodiments of earbud connectors that canbe used in the distal end of a stem portion of each earbud such asconnector 3060 in FIG. 30. As shown in FIG. 36, connector 3600 can beaffixed to a distal end 3055 of an earbud 3000 a, 3000 b and be used tocouple charging and data signals to the earbuds. Connector 3600 can bemated with receptacle connectors that can be disposed in a case ordocking station such as the receptacle connectors disclosed in FIGS.4A-8C.

Connector 3600 is illustrated in FIG. 36 in a partially assembled statebefore it is attached to a distal end 3055 of a stem portion 3015 ofearbud 3000 a, 3000 b. In this embodiment connector 3600 includes aninner circular metallic contact 3610 and an outer circular metalliccontact 3615 with a dielectric ring 3620 separating the two contacts. Invarious embodiments inner circular contact 3610 can have an aperture3613 within it that can be used for both a receptacle connector contactsurface and an aperture for a microphone. In some embodiments inner andouter circular contacts 3610, 3615, can be separately manufacturedcomponents and can be made from a metal or alloy that can have one ormore layers of plating, as described in more detail below. In variousembodiments inner and outer circular contacts 3610, 3615, can be madefrom a copper or copper-based alloy such as, but not limited to C5212phosphor bronze. In some embodiments inner and outer circular contacts3610, 3615, can be individually machined, cast or metal injectionmolded. In further embodiments they can be made from an electricallyconductive plastic or made from an insulative plastic that is platedwith one or more metals or alloys.

As shown in FIG. 37, connector 3600 includes inner and outer circularcontacts 3610, 3615, respectively that can be manufactured as separatecomponents. In one example inner and outer circular contacts 3610, 3615,include one or more ridges 3625 to enable increased retention force todielectric ring 3620. To electrically couple inner and outer circularcontacts 3610, 3615, to earbuds 3000 a, 3000 b the contacts can eachinclude coupling tabs. More specifically inner circular contact 3610 canhave a first coupling tab 3630 for attaching to a portion of flexiblecircuit 3225 (see FIGS. 34-36). In some embodiments first coupling tab3630 is soldered to a metallized pad 3635 (see FIG. 36) on flexiblecircuit 3225, however in other embodiments it can be attached with aconductive epoxy or other method. Outer circular contact 3615 can have asecond coupling tab 3640 for attaching to a portion of flexible circuit3225 similar to the aforementioned process.

As described above, outer circular contact 3615 can have an arcuatecross-section to facilitate wiping of a mating contact to provide areliable interconnect with a receptacle connector. Inner circularcontact 3610 can also have an arcuate or sloped cross-section to promotecontact wiping with a receptacle connector. In some embodiments innerand outer circular contacts 3610, 3615, can be plated with one or moremetals that can prevent oxidation of the contact surface for reducedinterconnect resistance and in further embodiments the plating can beused to provide an aesthetically appealing appearance, as described inmore detail below.

In various embodiments inner and outer circular contacts 3610, 3615, canbe plated first with a layer of nickel followed by a final layer ofgold. In some embodiments inner and outer circular contacts 3610, 3615,can be plated with a first layer of copper between 3 and 5 micronsthick, followed by a layer of gold between 0.5 and 0.7 microns thick,followed by a layer of gold between 0.1 and 0.2 microns thick, followedby a layer of palladium between 0.5 and 0.8 microns thick, followed by alayer of gold between 0.1 and 0.2 microns thick, followed by a binaryalloy layer including a first element and a second element, between 0.7and 1.0 microns thick.

In some embodiments inner and outer circular contacts 3610, 3615, can beplated with a first layer of copper between 3 and 4.5 microns thick,followed by a layer of gold between 0.5 and 0.9 microns thick, followedby a layer of palladium between 0.5 and 0.8 microns thick, followed by alayer of gold between 0.1 and 0.2 microns thick, followed by a binaryalloy layer including a first element and a second element, between 0.65and 1.0 microns thick.

In these and other embodiments of the present invention, the firstelement of the binary alloy layer may be an element in a first groupconsisting of platinum, palladium, iridium, osmium and rhodium. In theseand other embodiments of the present invention, the first element may berhodium.

In these and other embodiments of the present invention, the secondelement of the binary alloy layer may be an element in a second groupconsisting of platinum, palladium, iridium, osmium, and ruthenium. Inthese and other embodiments of the present invention, the second elementmay be ruthenium.

In these and other embodiments of the present invention, the firstelement may comprise approximately 85 weight percent of the binary alloywhile the second element may comprise approximately 15 weight percent ofthe binary alloy. In these and other embodiments of the presentinvention, the first element may comprise approximately 90 weightpercent of the binary alloy while the second element may compriseapproximately 10 weight percent of the binary alloy. In these and otherembodiments of the present invention, the first element may compriseapproximately 95 weight percent of the binary alloy while the secondelement may comprise approximately 5 weight percent of the binary alloy.In these and other embodiments of the present invention, the firstelement may comprise approximately 99 weight percent of the binary alloywhile the second element may comprise approximately 1 weight percent ofthe binary alloy. In these and other embodiments of the presentinvention, the first element may comprise more than or approximately99.5 weight percent of the binary alloy while the second element maycomprise less than or approximately 0.5 weight percent of the binaryalloy.

In some embodiments a combination of rhodium and ruthenium for thebinary alloy can be used to prevent oxidation of the contact surfacewhile providing an aesthetically appealing gray or silver appearance.Other combinations and compositions of plating are within the scope ofthis disclosure. In yet further embodiments first and second couplingtabs 3630, 3640 can be masked before the final layer of the binaryalloy, leaving them with a gold surface for improved solderability.

After inner and outer circular contacts 3610, 3615 are plated they canbe insert molded to form a connector 3600 as shown in FIG. 38. Adielectric ring 3620 can be molded in-between and around portions ofinner and outer circular contacts 3610, 3615, and can be used to formone or more attachment tabs 3655 that assist connector 3600 beingattached to earbud 3000 a, 3000 b as illustrated in FIG. 36.

Now referring to FIGS. 39 and 40 perspective views of connector 3900 areillustrated. As shown in FIGS. 39 and 40, connector 3900 is similar toconnector 3600 illustrated in FIG. 36, however connector 3900 includestwo semicircular contacts instead of circular inner and an outercontacts. An end view of connector 3900 is similar to the end view ofconnector 605 illustrated in FIG. 6B. Connector 3900 includes a firstsemicircular contact 3910 and a second semicircular contact 3915 with adielectric layer 3920 separating the two contacts. First and secondsemicircular contacts 3910, 3915, respectively, can be spaced in anoppositional and symmetrical relationship with each other. In variousembodiments first and second semicircular contacts 3910, 3915,respectively, can form an aperture 3913 between them that can be usedfor both a receptacle connector contact surface and an aperture for amicrophone. First and second semicircular contacts 3910, 3915,respectively, can be manufactured and plated using the same processesdescribed above with regard to connector 3600.

To electrically couple first and second semicircular contacts 3910,3915, respectively, to earbud 3000 a, 3000 b they can each includecoupling tabs similar to connector 3600. More specifically firstsemicircular contact 3910 can have a first coupling tab 3930 forattaching to a portion of flexible circuit 3225 (see FIGS. 34-36).Second semicircular contact 3915 can have a second coupling tab 3940 forattaching to a portion of flexible circuit 3225 similar to theaforementioned process.

After first and second semicircular contacts 3910, 3915, respectively,are plated they can be insert molded to form a connector 3900 as shownin FIG. 40. A dielectric layer 3920 can be molded in-between and aroundportions of first and second semicircular contacts 3910, 3915,respectively, and can be used to form one or more attachment tabs 3955that assist connector 3900 being attached to earbud 3000 a,b asillustrated in FIG. 36.

Capacitive Sensor Insert

FIG. 41 illustrates a simplified perspective view of earbud 4100. Asshown in FIG. 41, earbud 4100 includes a housing 4105 and a capacitivesensor insert 4110 that can sense a user's touch on exterior surface4115 of the housing. Capacitive sensor insert 4110 has sensor circuitry4120 that can create one or more capacitive sensors, as explained inmore detail below. For example, sensor circuitry 4120 can create a firstcapacitive sensor in region 4125 on exterior surface 4115 of housing4105 that can be used to detect the touch of a user's ear for in the earsensing and can create a second capacitive sensor in region 4130 thatcan be used to detect the touch of a user's finger to answer a call orto perform any other function.

FIG. 42 illustrates a simplified cross-section of earbud housing 4104.As shown in FIG. 42, housing 4105 includes a capacitive sensor insert4110 positioned within a cavity 4205 defined by the housing. Cavity canalso house one or more other components of the earbuds 3000 a,b. Earbudhousing 4105 has at least one touch sensitive region 4125, 4130 atexterior surface 4115 of the housing that is formed by capacitive sensorinsert 4110. Housing 4105 has an interior surface 4210 within cavity4205, opposite exterior surface 4115. Capacitive sensor insert 4110 hasa first surface 4215 with metalized sensor circuitry 4120 (see FIG. 41)that is positioned adjacent interior surface 4210 of housing 4105.Capacitive sensor insert 4110 has a second surface 4220 that is oppositefirst surface 4215.

FIGS. 43 and 44 illustrate simplified plan views of capacitive sensorinserts 4300, 4400, respectively. As shown in FIGS. 43 and 44, differenttypes of circuitry can be used to form the capacitive sensors, forexample in FIG. 43 self-capacitance circuitry can be used and in FIG. 44mutual-capacitance sensor circuitry can be used.

Now referring to FIG. 43, a plan view of sensor insert 4300 isillustrated. As shown in FIG. 43, sensor insert 4300 hasself-capacitance sensor circuitry 4305 that senses the touch of a user(e.g., the user's ear and/or finger) on exterior surface 4115 (see FIG.42) of housing 4105. The user's touch loads the self-capacitancecircuitry and/or increases the parasitic capacitance to ground which isinterpreted by the sensor insert 4300 and communicated to the earbudprocessor. Sensor circuitry 4305 can have one or more interconnectregions 4310, for example solder pads or plated through holes, thatallow it to be coupled to an earbud processor with one or moreconductors.

In one embodiment sensor insert 4300 can be formed from a plastic thatincludes metallic particulates. A laser can then be used to laseractivate regions 4315 on first surface 4320 of sensor insert 4300, thatcorrespond to the desired location of sensor circuity 4305. The laseractivated regions can then be metallized in a plating bath. In oneexample metal circuitry can be plated on to the activated regionsforming sensor circuitry 4305. This process may be known in the art aslaser direct structuring. Other methods can be used for form sensorinsert 4300 without departing from this disclosure. For example inanother embodiment a flexible circuit can be adhered to first surface4320 of sensor insert and used as the sensor circuitry. In anotherexample first surface 4320 can be entirely plated and can be etchedusing a photo-imageable ink.

In further embodiments sensor insert 4300 can have one or more acousticapertures 4325 that allow sound to pass through and can be aligned witha sound port of the earbuds. In some embodiments insert 4300 can beformed in a hemispherical or other shape to closely match a shape of theexternal earbud housing. Additionally, in some embodiments, sensorcircuitry 4305 can fully surround or partially surround the acousticapertures.

Now referring to FIG. 44, a plan view of sensor insert 4400 isillustrated. As shown in FIG. 44, sensor insert 4400 hasmutual-capacitance sensor circuitry 4405 that senses the touch of a user(e.g., the user's ear and/or finger) on exterior surface 4115 (see FIG.42) of housing 4105. The user's touch alters the mutual coupling betweenrow and column electrodes 4410, which are scanned sequentially andcommunicated to the earbud processor. Sensor circuitry 4405 is formed onfirst surface 4407 of sensor insert 4400 and can have one or moreinterconnect regions 4415, for example solder pads or plated throughholes, that allow it to be coupled to earbud processor with one or moreconductors.

As described above with regard to sensor insert 4300 in FIG. 43, sensorinsert 4400 can be manufactured in the same way and can have similarfeatures and functions. Additionally, in some embodiments sensor insert4400 can include one or more acoustic apertures 4425 that allow sound topass through sensor circuitry 4305 and at least some of sensor circuitry4405 can fully surround or partially surround the acoustic apertures.Additionally, in some embodiments sensor insert 4400 can be formed in ahemispherical or other shape to closely match a shape of the externalearbud housing.

Acoustic Insert

FIG. 45A illustrates a simplified rear perspective view of earbud 3000a. As shown in FIG. 45A, earbud 3000 a includes an acoustic insert 4505(shown in dashed lines within housing 3005 and in solid lines outside ofthe housing) that can be used to provide venting for driver (e.g.,speaker) in earbud 3000 a. More specifically, acoustic insert 4505 canbe used to assist in forming a bass port 3040 and a rear vent 3035, thatcombine into a multiport 3030. In some embodiments, certain features ofacoustic insert 4505 can be useful for forming acoustic vents in arelatively small and confined area such as an earbud housing.

Earbud 3000 a can have multiple acoustic apertures, some of which areshown in FIG. 30. In addition to bass port 3040, rear vent 3035 andmultiport 3030, each earbud can also have a directional sound port 3020and a front leak port 3025. These apertures can provide venting for thedriver, sound for the user, and can help tune the frequency response ofearbud 3000 a. More specifically, each aperture is not just a randomopening, but instead can be intentionally formed for a particularpurpose, namely to change the frequency response of ear bud 3000 a in away that helps to tune the frequency response and/or provide aconsistent bass response amongst the same user and across users. Theacoustic apertures can each also include various meshes (e.g., adirectional sound port mesh, front leak mesh, back vent mesh, bass portmesh, and a multiport mesh) that cover or fit into a correspondingacoustic aperture of earbud 3000 a.

FIG. 45B illustrates a simplified side view of earbud 3000 a withacoustic insert 4505. As shown in FIG. 45B, acoustic insert 4505 anddriver 4570 are disposed within housing 3005 (illustrated in dashedlines). Now referring simultaneously to FIGS. 45A and 45B the functionof acoustic insert 4505 is described in more detail. Driver 4570 can bepositioned within cavity 4510 of housing 3005, forming a front volume4515 in front of the driver and a back volume 4520 behind the driver.Driver 4570 can be positioned such that front volume 4515 isacoustically isolated from a back volume 4520. Front and back volumes4515, 4520, respectively can be formed within cavity 4510 at leastpartially by housing 3005 and sized and shaped to achieve a desiredfrequency response of the earbud.

In some embodiments, portions of acoustic insert 4505 are formed toclosely match the contours of an interior surface 4525 of housing 3005.More specifically, raised regions 4530 of acoustic insert 4505 can beformed to fit securely against interior surface 4525 such that they canbe bonded to interior surface 4525 forming a bass port channel 4527 anda multiport chamber 4507 that are acoustically sealed. That is, bassport channel 4527 can be formed by first, second and third walls 4535,4540, 4545, respectively of bass port recess 4550 and a fourth wallformed by interior surface 4525 of housing 3005. Similarly, raisedregions 4530 can be sealed to interior surface 4525 forming multiportchamber 4507 that is acoustically sealed.

Bass port channel 4527 can have an entrance aperture 4555 thatcommunicates with back volume 4520. Bass port channel 4527 can be routedfrom entrance aperture 4555 to an exit aperture 4560 that is formedwithin multiport chamber 4507 that can be vented to the ambient. Rearvent 3035 can also be routed to multiport chamber 4507, providing a ventfrom back volume 4520 through rear vent aperture 4565 in acoustic insert4505 to multiport chamber 4507. The size and shape of bass port channel4527 and rear vent aperture 4565 can be formed for a particular purpose,namely to change the frequency response of ear bud 3000 a in a way thathelps to tune the frequency response and/or provide a consistent bassresponse amongst the same user and across users.

Housing 3005 can serve as a housing for the remaining components of theearbud assembly and can be formed in any suitable manner and can be madefrom any suitable material. For example, in one embodiment housing 3005is made from a molded plastic. Similarly, acoustic insert 4505 can bemade from any suitable material including a molded plastic.

Myriad methods can be used to bond raised regions 4530 of acousticinsert to interior surface 4525 of housing 3005. In one embodimenthousing 3005 can be made from an ABS plastic that is substantiallytransparent, or at least semitransparent to the wavelength of a laser(FIG. 46, step 4605). Acoustic insert 4505 can be made from a plasticthat is opaque or at least mostly opaque to the same laser (FIG. 46,step 4610). Acoustic insert 4505 can be placed within cavity 4510 ofhousing 3005 such that raised regions 4530 are firmly against interiorsurface 4525 (FIG. 46, step 4615). A laser beam from the laser can thenbe directed through housing 3005 such that it impinges raised regions4530, melting at least a portion of the raised regions and bonding themto interior surface 4525 of housing 3005 (FIG. 46, step 4620).

In some embodiments, to enable the laser to be directed through housing3005, housing 3005 can use a relatively low amount of pigment, a pigmentthat is transparent to the laser, or other features to allow the laserto be transmitted through the housing with enough energy to melt atleast a portion of raised regions 4530. Acoustic insert 4505 can be madefrom a plastic that contains an absorptive dopant, such as carbon, so itabsorbs the laser energy. In one embodiment a laser system that issimilar to a laser direct structuring laser can be used to perform thelaser bonding operation. In other embodiments raised regions 4530 can bebonded to interior surface 4525 with other methods such as, but notlimited to, a pressure sensitive adhesive, a heat activated film or alaser activated adhesive.

Wireless Pairing

FIGS. 47-49 illustrate a wireless pairing system 4700 that includes apair of wireless headphones 4710 (e.g., a pair of wireless earbuds) thatcan be wirelessly paired to a host device 4715 (e.g., a computer, asmartphone, a tablet computer, a smart watch, or the like), with thepairing initiated by an intermediate device 4705 (e.g., a case for theheadphones). Intermediate device 4705 can instruct wireless headphones4710 to enter a pairing sequence with host device 4715 in response to auser input. The user input can be a user-initiated event, such asopening earbud case lid 4720 or depressing an input button 4725. In someembodiments headphones 4710 can receive the pairing instruction via awired connection between intermediate device 4705 and wirelessheadphones 4710 (e.g., through mated electrical contacts in a case for apair of wireless earbuds and the earbuds as described above). In otherembodiments, intermediate device 4705 can include a wireless radio thatcommunicates the instruction to the wireless radio within wirelessheadphones 4710. Upon receiving the pairing instruction, headphones 4710can initiate a pairing sequence to host device 4715 via a wirelesscommunication protocol (e.g., via Bluetooth®) that supportsbidirectional data transfer.

In some cases, headphones 4710 are a pair of wireless earbuds and onlyone earbud in the pair (i.e., a primary earbud) is paired with thecompanion host device 4715. In such cases, the primary earbudcommunicatively couples with the other earbud (a secondary earbud) sothat audio data received from host device 4715 by the primary wirelessearbud can be shared with the communicatively coupled secondary wirelessearbud.

In some embodiments, headphones 4710 do not include a user inputmechanism, such as a button that can be pressed for a user to initiatepairing between the headphones and host device 4715, and wirelesspairing between intermediate device 4705 and host device 4715 can onlybe initiated via intermediate device 4705 (e.g., in response touser-input by either opening the case lid or pressing an input button onthe case or other suitable means) or by host device 4715.

FIG. 48 illustrates a wireless pairing system 4800 according to anembodiment of the present disclosure that includes intermediate device4705, headphones 4710 and host device 4715 shown in FIG. 47. While FIG.48 illustrates simplified block diagrams of each of intermediate device4705, wireless headphones 4710 and host device 4715, it is understoodeach of the illustrated devices can include functions and features inaddition to those illustrated in FIG. 48. For example, while not shownin FIG. 48, each of intermediate device 4705, wireless headphones 4710and host device 4715 can include a battery, such as a rechargeablebattery, that provides power to the various components of each device.

In some embodiments, host device 4715 can be an electronic device orportable media player, such as an iPod™ media player manufactured andsold by Apple Inc., assignee of the present application. In general, amedia player can be any device capable of storing and playing mediaassets including, but not limited to, audio, video, and/or still images.Alternatively, host device 4715 can be a mobile phone (e. g., usingconventional cellular communication technology), a personal digitalassistant (PDA), or a multifunctional device that incorporates acombination of media player, mobile phone, and/or PDA capabilities, suchas an iPhone™ mobile device produced and sold by Apple, Inc. Host device4715 can also be a general-purpose computer, such as a handheldcomputer, laptop computer, desktop computer, or the like.

Host device 4715 includes a processor 4820, a memory 4825, a userinterface 4830, a first wireless transceiver 4835 (e.g., a Bluetoothtransceiver), a second wireless transceiver 4840 (e.g., a cellulartransceiver) and a wired input/output 4845. Processor 4820, which can beimplemented as one or more integrated circuits, can control theoperation of host device 4715. For example, in response to user inputsignals provided by a user through user interface 4830, processor 4820can initiate programs to search, list or play media assets stored inmemory 4825. In communication with cellular transceiver 4840, processor4820 can control placing and receiving of telephone calls. Secondtransceiver 4840 can also be used to communicate data with a network,including network storage 4815. First transceiver 4835 can be used tosupport short range wireless communication (e.g., Bluetoothcommunication) between host device 4715 and various accessory devices,including headphones 4710. Memory 4825 can store any information,including Bluetooth pairing information as described in more detailbelow. Wired input/output 4845 can be any wired connection, such as aUSB protocol or a proprietary protocol, such as that used by the AppleLightning connector.

Wireless headphones 4710 can be traditional headphones that are wornover a user's head, headsets (a combination of a headphone and amicrophone), earbuds (very small headphones that are designed to befitted directly in a user's ear) or any other portable listening device.In some embodiments wireless headphones 4710 include a processor 4850, awired input/output 4855, a memory 4860 and a wireless transceiver 4865(e.g., a Bluetooth transceiver).

Processor 4850, which can be implemented as one or more integratedcircuits, can control the operation of headphones 4710. Wiredinput/output 4855 can be any wired connection between intermediatedevice 4705 and wireless headphones 4710 including a proprietaryinterconnection. In one example wired input/output 4855 is an electricalconnector, such as connector 347 (see FIG. 3) or any of the connectorsillustrated in FIGS. 4A-8C, that provides a direct electrical connectionbetween wireless headphones 4710 and intermediate device 4705 when theheadphones are mated with the intermediate device (e.g., stored in acase). Wired input/output 4855 can be used for charging wirelessheadphones 4710 and/or communicating data with intermediate device 4705.In one example, wired input/output 4855 of headphones 4710 can be usedto receive a signal from wired input/output 4875 of intermediate device4705 to initiate a pairing sequence of the headphones, as described inmore detail below.

Wireless transceiver 4865 can be used to support short range wirelesscommunication (e.g., Bluetooth communication) between headphones 4710and various host devices, including host device 4715. In one embodiment,intermediate device 4705 may also be equipped with a wirelesstransceiver (not shown; e.g., a Bluetooth transceiver) that canwirelessly communicate with wireless transceiver 4865. Wirelesstransceiver 4865 enables headphones 4710 to communicate wirelessly withhost device 4715 once a channel for wireless communication has beenestablished between the two. For example, headphones 4710 and hostdevice 4715 may each be provided with Bluetooth® technology, includingappropriate short-range transceiver units. In some embodiments, it maybe possible to establish a Bluetooth® pairing between host device 4715and headphones 4710 using conventional techniques, such as manual entryof a passcode (or PIN code) associated with headphones 4710 into hostdevice 4715. In other embodiments, Bluetooth® pairings can beestablished automatically as described below.

Memory 4860 can store firmware for operating headphones 4710 as well asdata for coupling with other wireless ear buds and for pairingheadphones 4710 with companion host devices. For example, memory 4860can store a connection history for companion host devices such as hostdevice 4715, with which headphones 4710 have previously paired. Theconnection history can include data for automatically pairing headphones4710 with the companion host device without having to configure aconnection between the headphones and the companion host device (e.g.,enter a password, exchange shared secrets, etc.). For example, theconnection history can include one or more link keys for connecting to awireless network (e.g., Bluetooth link keys). Memory 4860 can also storea MAC address that uniquely identifies headphones 4710 as well as storea paired partner MAC address of another headphone that has previouslycoupled with the wireless ear bud 165. For example, in one embodimentheadphones 4710 are wireless earbuds and memory 4860 can store the MACaddress of a paired partner earbud.

In another example once headphones 4710 are paired with host device4715, the host device can save related pairing information fromheadphones 4710 to a network storage system 4815 such as cloud storage.In one embodiment the related pairing information stored in networkstorage 4815 can then be used by other host devices to be pre-pairedwith wireless headphones 4710. As an illustrative example, in oneembodiment wireless headphones are initially paired with an iPhone. TheiPhone communicates the pairing information to the user's iTunes oriCloud account that is saved on a remote network separate from hostdevice 4715 (e.g., in the iCloud). The wireless headphones will then belisted on the user's iTunes or iCloud account as an authorized wirelessdevice for the account. For example, the user's iCloud account mayinclude a first list of host devices (one or more smart phones, one ormore tablet computers and one or more laptop computers) including hostdevice 4715 that are automatically authorized, for example based on theprevious authorization and/or authentication of the devices to theiCloud account, to be paired with one or more wireless headphones thathave been added to the account (including wireless headphones 4710). Theuser can then go to their iPad which can be automatically paired to theheadphones without having to initiate a separate pairing sequencebetween headphones 4710 and the iPad based on the list of approvedpairing in the user's iCloud account. Multiple host devices can bepre-authorized and automatically paired using this feature.

In some embodiments, intermediate device 4705 can be a case forheadphones 4710, a docking station, or another type of accessory orelectronic device. In some embodiments intermediate device 4705 includesa processor 4870, a wired input/output 4875, and a user input device4880 and a memory 4885.

Processor 4870, which can be implemented as one or more integratedcircuits, can control the operation of intermediate device 4705 byexecuting computer instructions stored in a computer-readable memory ormedium, such as memory 4885. For example, instructions stored withinmemory 4885 can cause processor 4870 to, in response to user inputsignals provided by user input device 4880, send an instruction toheadphones 4710 (e.g., via wired I/O interface 4875 or by a wirelesschannel between intermediate device 4705 and wireless headphones 4710)to enter a pairing sequence with a host device. Wired input/output 4875can be any wired connection between intermediate device 4705 andwireless headphones 4710 including a proprietary interconnection. In oneexample wired input/output 4855 is a portion of an electrical connector347 (see FIG. 3) between pair of earbuds 115 a, 115 b and case 100 andcan be any connector illustrated in FIGS. 4A-8C. Wired input/output 4855can be used for charging and/or data. In various embodiments wiredinput/output 4855 can be used to transmit a signal to headphones 4710 toinitiate a pairing sequence, as described in more detail below.

User input device 4880 can be any device operable by a user. In oneembodiment user input device 4880 is a lid sensor such as lid sensor 220(see FIG. 2) that detects an opening or a closing of a lid ofintermediate device 4705. In one example an opening event is detectedand processor 4870 sends a signal through wired input/output 4875 ofintermediate device to wired input/output 4855 of headphones toprocessor 4850 of headphones 4710 to initiate a pairing sequence and/orto turn on Bluetooth transceiver 4865. In another example, wirelessheadphones 4710 have never been paired before and headphones 4710 entera pairing sequence. In a further example headphones 4710 have beenpaired before and headphones 4710 activate Bluetooth transceiver 4865but do not initiate a pairing sequence. In one embodiment intermediatedevice 4705 may include one or more indicator lights to notify a userthat it has sent a pairing signal to headphones 4710.

FIG. 49 describes a method 4900 in which an intermediate device (e.g.,intermediate device 4705) initiates wireless pairing between a hostdevice (e.g., host device 4715) and a pair of wireless headphones (e.g.,wireless headphones 4710). The method set forth in FIG. 49 can becarried out by, for example, a processor within the intermediate deviceexecuting computer instructions stored within a computer-readable memory(e.g., processor 4870 executing instructions stored in computer-readablememory 4885). In step 4905 the intermediate device receives a userinput. In some embodiments the intermediate device is a case for a pairof headphones or a pair of earbuds. In various embodiments the userinput can be opening a lid of the case, depressing a button on the caseor doing anything else to the case that the case registers as a userinput indicative of a desire to initiate the pairing sequence. In oneparticular example, when a user opens a lid of the case, a lid sensorsends a signal to processor 4870 notifying the processor that the lidhas been opened.

In step 4910, in response to receiving the user input, the intermediatedevice determines if the headphones are connected to the intermediatedevice. For example, in some embodiments the intermediate device is anearbud case and the pair of wireless headphones is a pair of wirelessearbuds that fit within earbud receiving cavities of the case. Theearbud case can include one or more earbud detectors as described abovethat can generate a signal indicating whether and can determine whetherthe earbuds are stored within the case as described above and provide asignal to the processor indicating whether the earbuds are stored withinthe case. As one particular example, an earbud case can determine ifearbuds are stored within the case based on whether one or moreelectrical contacts on the earbuds are electrically connected to one ormore electrical contacts within the case. In another embodiment theintermediate device is a docking station that couples to the headphoneswith a mating connector. If some embodiments, if the headphones are notconnected to intermediate device there is no action taken by theintermediate device (step 4912), while if the headphones are connectedto the intermediate device the method proceeds to step 4915. In otherembodiments, step 4910 is optional and the intermediate device proceedswith step 4915 regardless. In such embodiments, however, if theheadphones are not communicatively coupled to the intermediate device,the headphones will not receive the instruction generated in step 4915and thus the end result of method 4900 in such cases will be “no actiontaken” (step 4912).

In step 4915, in response to the intermediate device determining thatthe headphones are connected to the intermediate device, theintermediate device transmits an “initiate pairing” instruction orsignal to the headphones. In one embodiment the intermediate devicetransmits the “initiate pairing” signal through a charging connectionbetween the headphones and the intermediate device. In anotherembodiment the intermediate device can send the signal wirelessly to theheadphones. In one example different user inputs result in theintermediate device transmitting different “initiate pairing” signals tothe headphones that are distinguishable by the headphones. As oneexample where the intermediate device is a case for a pair of earbuds,the case can transmit an instruction to the earbuds to automaticallypair with a known and previously paired host when the lid opened. If,the input button is depressed, either before or after the lid is opened,the case can transmit an instruction to the earbuds to enter a discoverymode instead of the automatic pairing mode. The discovery mode thenenables the earbuds to be selectively paired by a user to a differenthost device using a standard pairing sequence. In some embodiments, asdescribed above, step 4910 is optional and intermediate device transmitsan “initiate pairing” request signal to the headphones withoutattempting to determine if the headphones are connected, but if theheadphones are not connected, the signal will not be received.

In step 4920 the headphones receive the “initiate pairing” signal fromthe intermediate device through an electrical connector, or through awireless connection.

In step 4925, in response to receiving the “initiate pairing” signal,the headphones determine if a pairing sequence should be initiated. Inone embodiment the headphones examine a pairing memory within theheadphones and determine if this is a first pairing or a subsequentpairing of the headphones. If it is a first pairing the headphoneprocessor can determine what type of user input was received todetermine if pairing should be initiated. For example, for a firstpairing (e.g., the pairing memory of the headphones is empty) if a useropened the lid, pairing can be initiated, but if a user pushed a buttonpairing is not initiated. However, if this is a subsequent pairing(e.g., the pairing memory of the headphones has at least one registry),if a user opens the lid pairing is not initiated but if a user pushed abutton then pairing is initiated. These are only examples and otherlogic sequences are within the scope of this disclosure.

In a further example the headphones will only pair to a host devicewithin a predetermined proximity of the headphones. In one example theheadphones will only pair to a host electronic device within 10 meters,while in another embodiment it must be within 5 meters and in a furtherembodiment within 3 meters and in yet another embodiment within 1 meter.The maximum proximity pairing distance between the headphones and hostdevice can be set at either the headphones or at the host device.

In some embodiments, the distance can be controlled by the headphones bythe strength of the wireless signal sent from the headphones to the hostdevice. For example, the headphones can broadcast a pairing signal thatis at a predetermined reduced power level to insure that the electronicdevice is within a desired proximity. In one embodiment the headphonesmay broadcast a pairing signal that is 80% or less of its normalbroadcasting power (i.e., its normal signal strength). In anotherembodiment the pairing signal may be 50% or less of the normal signalstrength and in a further embodiment it may be 25% or less of the normalsignal strength.

In some embodiments, the distance can be controlled by the hostelectronic device based on the strength of the signal received from theheadphones. For example, in some embodiments the host electronic devicewill only accept the wireless pairing request from the first device ifthe strength of the wireless signal transmitting the pairing request isabove a predetermined threshold that is higher than a minimum signalstrength required for normal wireless communication between the firstand second devices. In one embodiment the predetermined threshold is200% higher than the normal minimum signal strength required forwireless communication between the headphones and host device. Inanother embodiment the predetermined threshold is 150% higher than thenormal minimum signal strength and in still further embodiments it canbe 100% or 50% higher than the normal minimum signal strength.

Regardless of the approach taken, if the host electronic device is notsufficiently proximate the headphones, the headphones will not accept(or will not receive) the pairing request and no further action toconsummate the pairing is taken (step 4927). However if the requiredconditions are met, the method proceeds to step 4930.

In step 4930, in response to the headphones determining that a pairingsequence should be initiated (or should continue), the headphonestransmit a wireless pairing signal using a wireless protocol commonbetween the headphones and host device. In some embodiments this may bea standardized recurring Bluetooth signal that can stop after apredetermined period of time if there is no answer. In otherembodiments, other known wireless protocols can be used.

In step 4935, in response to receiving the pairing signal, the hostdevice authenticates and pairs the headphones. In one example the hostdevice provides the user a prompt asking if pairing should be performedbefore pairing the headphones. If the user accepts, the host devicesends data to the headphones and authentication of the headphones isperformed.

In some instances, prior to initiating a wireless pairing sequencebetween a pair of wireless headphones and a host device, a case for apair of wireless earbuds according to the present disclosure canautomatically turn ON the wireless radio of the earbuds when a useropens the lid that encloses the earbuds within the case. FIG. 50illustrates a method 5000 in which an earbud case (e.g., intermediatedevice 4705) turns ON the wireless radio of a pair of earbuds (e.g.,wireless headphones 4710) stored within the case according to someembodiments of the disclosure. As shown in FIG. 50, method 5000 canstart when intermediate device 4705 detects that lid 4720 is moved froma closed position to an open position (step 5005).

If the earbuds are not in the case, then no action is taken (step 5020).If wireless headphones 4710 are within the case (step 5010), the casecan generate and send an instruction to the pair of earbuds that causesthe earbuds to turn their wireless radio on. In some embodiments theinstruction can be sent over one or more electrical contacts positionedwithin the receiving cavity as described above. Once the earbuds turntheir wireless radio on, the buds can be further instructed to initiatea pairing sequence with a host device. In some embodiments, a singleuser interaction with the case (e.g., opening lid 4720 or depressingbutton 4725) can generate instructions that are sent to the earbuds toboth turn on the earbud wireless radio and initiate a pairing sequenceas described with respect to FIG. 49. In some embodiments a singleinstruction from intermediate device 4705 can initiate both actions andin other embodiments the case can send multiple instructions in responseto the single event.

In other embodiments, the closure of lid 4720 can automatically turn OFFthe wireless radio in the earbuds as described with respect to FIG. 51,which illustrates a method 5100 according to some embodiments of thedisclosure. As shown in FIG. 51, method 5100 can start when intermediatedevice 4705 detects that lid 4720 is moved from an open position to aclosed position (step 5105). If the earbuds are not in the case, then noaction is taken (step 5120). If wireless headphones 4710 are within thecase (step 5110), the case can generate and send an instruction to thepair of earbuds that causes the earbuds to turn OFF their wireless radiothus saving charge of the batteries within the earbuds.

While the various embodiments and examples described above wereprimarily focused on earbuds and a case for storing such earbuds,embodiments of the disclosure are not limited to such and the techniquesof the disclosure described above are equally applicable to headphonesand other listening devices and cases for such. For example, in oneembodiment, case 100 described in FIG. 1 can be a case for a pair ofheadphones instead of a pair of earbuds. In such an embodiment, cavities110 a, 110 b can be sized and shaped to hold left and right earpads ofthe headphones along with portions of a band connecting the two earpads.In other embodiments, a single cavity can be included in the case tohold the earpads and some or all of the connecting headband. Similarly,in other embodiments, case 100 can be sized and shaped to hold aportable speaker or other type of listening device.

For simplicity, various internal components, such as circuitry, bus,memory, storage devices and other components of pair of earbuds 115 a,115 b, case 100 (see FIG. 1) and wearable electronic device 2301 (seeFIG. 23) are sometimes not shown in the figures. Also, it is noted thatsome embodiments have been described as a process that is depicted as aflow diagram or block diagram. Although each diagram may describe theprocess as a sequential series of operations, many of the operations canbe performed in parallel or concurrently. In addition, the order of theoperations may be rearranged. A process may have additional steps notincluded in the figures.

In the foregoing specification, embodiments of the disclosure have beendescribed with reference to numerous specific details that may vary fromimplementation to implementation. The specification and drawings are,accordingly, to be regarded in an illustrative rather than a restrictivesense. The sole and exclusive indicator of the scope of the disclosure,and what is intended by the applicants to be the scope of thedisclosure, is the literal and equivalent scope of the set of claimsthat issue from this application, in the specific form in which suchclaims issue, including any subsequent correction. The specific detailsof particular embodiments may be combined in any suitable manner withoutdeparting from the spirit and scope of embodiments of the disclosure.Additionally, spatially relative terms, such as “bottom” or “top” andthe like may be used to describe an element and/or feature'srelationship to another element(s) and/or feature(s) as, for example,illustrated in the figures. It will be understood that the spatiallyrelative terms are intended to encompass different orientations of thedevice in use and/or operation in addition to the orientation depictedin the figures. For example, if the device in the figures is turnedover, elements described as a “bottom” surface may then be oriented“above” other elements or features. The device may be otherwise oriented(e.g., rotated 90 degrees or at other orientations) and the spatiallyrelative descriptors used herein interpreted accordingly.

What is claimed is:
 1. A case for an earbud, the case comprising: ahousing having a bottom wall and at least one sidewall extending fromthe bottom wall to define a chamber; an insert positioned within thechamber and defining: a receiving opening arranged to receive at least aportion of the earbud; an earbud section that communicates with thereceiving opening and is sized to receive a first portion of an earregion of the earbud such that a second portion of the ear region ispositioned outside of the receiving opening when the earbud ispositioned in the housing; and an elongated stem section thatcommunicates with the earbud section and is sized to receive a stemregion of the earbud; a bracket secured to the elongated stem sectionand including an electrical contact assembly comprising first and secondelectrical contacts extending into the elongated stem section andarranged to make electrical contact with the earbud when the earbud ispositioned within the housing; an electrical receptacle connector havingan opening at an exterior surface of the housing; and a lid operablebetween a closed position where the lid covers the receiving opening,and an open position where the lid exposes the receiving opening.
 2. Thecase of claim 1 wherein the elongated stem section extends from theearbud section towards the bottom wall.
 3. The case of claim 1 furthercomprising a rechargeable battery disposed within the housing andcoupled to the first and second electrical contacts to recharge theearbud when it is positioned within the housing.
 4. The case of claim 3further comprising an inductive charging coil positioned within thehousing and configured to transfer power from an external chargingdevice to the rechargeable battery.
 5. The case of claim 1 furthercomprising a button positioned at an external surface of the housing andconfigured to transmit a signal to the earbud when the earbud ispositioned within the housing.
 6. The case of claim 1 wherein thereceiving opening of the insert is positioned proximate a top portion ofthe housing.
 7. The case of claim 1 wherein the sidewall defines aperimeter of the chamber and includes an upper edge opposite the bottomwall; and wherein the lid is coupled to the housing by a hinge at theupper edge.
 8. A case for a pair of earbuds comprising: a housing havinga bottom wall and at least one sidewall extending from the bottom wallto define a chamber having a receiving aperture, the receiving aperturepositioned opposite the bottom wall; an insert positioned within thechamber, the insert defining first and second cavities sized and shapedto accommodate first and second earbuds of the pair of earbuds,respectively, each of the first and second cavities having: a receivingopening positioned proximate the receiving aperture and arranged to atleast partially receive each respective earbud into each respectivecavity; an earbud section that communicates with the receiving openingand is sized to accommodate an ear portion of each respective earbud;and an elongated stem section that communicates with the earbud section,extends toward the bottom wall and is sized to accommodate a stemportion of each respective earbud; a bracket secured to the insert andincluding an electrical contact assembly, the electrical contactassembly comprising first and second pairs of electrical contacts, eachpair of electrical contacts extending into each respective cavity tomake electrical contact with each respective earbud; an electricalconnector aperture defined by the housing and positioned to allow accessto an electrical receptacle connector disposed in the housing; and a lidoperable between a closed position where the lid covers the first andsecond cavities, and an open position where the lid exposes the firstand second cavities.
 9. The case of claim 8 wherein the first pair ofelectrical contacts includes a first and a second electrical contactpositioned in the first cavity, and wherein the second pair ofelectrical contacts includes a third and a fourth electrical contactpositioned in the second cavity.
 10. The case of claim 8 furthercomprising earbud detector circuitry coupled to the first and secondpairs of electrical contacts and configured to generate a detectionsignal when an earbud of the pair of earbuds is coupled to the first orsecond pairs of electrical contacts.
 11. The case of claim 8 furthercomprising a rechargeable battery disposed within the housing andcoupled to the first and second pairs of electrical contacts to rechargethe pair of earbuds when they are positioned within the housing.
 12. Thecase of claim 11 further comprising an inductive charging coilpositioned within the housing and configured to transfer power from anexternal charging device to the rechargeable battery.
 13. The case ofclaim 8 further comprising a button positioned at an external surface ofthe housing and configured to transmit a signal to the pair of earbudswhen the pair of earbuds are positioned within the housing.
 14. The caseof claim 8 wherein the sidewall defines a perimeter of the chamber andincludes an upper edge opposite the bottom wall; and wherein the lid iscoupled to the housing by a hinge at the upper edge.
 15. A case for apair of earbuds, the case comprising: a plastic housing having a bottomwall and one or more side walls that define an interior space; an insertpositioned within the interior space of the plastic housing andincluding an upper portion having a substantially flat upper surface andfirst and second legs extending away from the upper surface towards thebottom wall of the plastic housing, the insert defining first and secondreceiving cavities, the first receiving cavity including a firstelongated tube portion that extends along a length of the first leg andopens to a first earbud receiving portion formed in the upper portionand having an opening at the upper surface of the insert and the secondreceiving cavity including a second elongated tube portion that extendsalong a length of the second leg and opens to a second earbud receivingportion formed in the upper portion and having an opening at the uppersurface of the insert, wherein each of the first and second elongatedtube portions is sized and shaped to accommodate a stem portion of anearbud and the each of the first and second earbud receiving portions issized and shaped to partially accommodate an ear interfacing portion ofan earbud; a bracket disposed within the plastic housing and secured tothe first and second legs at a distal end of each leg, the bracketincluding: a first pair of electrical contacts extending into the firstelongated tube portion; and a second pair of electrical contactsextending into the second elongated tube portion; a rechargeable batteryand earbud charging circuitry disposed within the plastic housing andelectrically coupled to the first and second pairs of electricalcontacts; and a lid pivotably coupled to the plastic housing by a hingeand operable between a closed position where the lid covers the firstand second receiving cavities and an open position that exposes thefirst and second receiving cavities enabling an earbud to be placedwithin or taken out of the first or second receiving cavities.
 16. Thecase for a pair of earbuds as set forth in claim 15 further comprising:an inductive charging coil and battery charging circuitry disposedwithin the plastic housing and configured to wirelessly receive powerfrom a charging device and charge the rechargeable battery; and areceptacle connector having an opening at an external surface of theplastic housing and including a plurality of contacts disposed withinthe opening and configured to receive power from a charging device andcharge the rechargeable battery.
 17. The case of claim 15 furthercomprising a button positioned at an external surface of the housing andconfigured to transmit a signal to the pair of earbuds when the pair ofearbuds are positioned within the housing.
 18. A case for a pair ofearbuds, the case comprising: a plastic housing having a bottom wall andone or more side walls that define an interior space; an insertpositioned within the interior space of the housing and defining firstand second receiving cavities, each of the first and second receivingcavities including an elongated tube portion extending from a distal endadjacent the bottom wall to an earbud receiving opening disposed at anupper surface of the insert, wherein the elongated tube portion is sizedand shaped to accommodate a stem portion of an earbud and the earbudreceiving opening is shaped to partially accommodate an ear interfacingportion of an earbud; a bracket secured to the insert at the distal endsof each tube portion, the bracket including: a first pair of electricalcontacts extending into the-elongated tube portion of the firstreceiving cavity; and a second pair of electrical contacts extendinginto the elongated tube portion of the second receiving cavity; arechargeable battery and earbud charging circuitry disposed within theplastic housing and electrically coupled to the first and second pairsof electrical contacts; and a lid pivotably coupled to the plastichousing by a hinge and operable between a closed position where the lidcovers the first and second receiving cavities and an open position thatexposes the first and second receiving cavities enabling an earbud to beplaced within or taken out of the first or second receiving cavities.19. The case for a pair of earbuds as set forth in claim 18 furthercomprising: an inductive charging coil and battery charging circuitrydisposed within the plastic housing and configured to wirelessly receivepower from a charging device and charge the rechargeable battery; and areceptacle connector having an opening at an external surface of theplastic housing and including a plurality of contacts disposed withinthe opening and configured to receive power from a charging device andcharge the rechargeable battery.
 20. The case of claim 18 furthercomprising a button positioned at an external surface of the housing andconfigured to transmit a signal to the pair of earbuds when the pair ofearbuds are positioned within the housing.